Hot Forging Mould Channels for Uniform Internal Lubrication
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Solution Overview
Problem
Current hot forging processes face inefficiencies in lubrication, leading to wastage of lubricating-cooling liquid, inhomogeneous surface coverage, increased maintenance needs, and thermal fatigue due to excessive lubricant use and uncontrolled diffusion, which affects the quality of the final product and the longevity of equipment.
Innovation Solution
A mould design featuring internal feeding channels and distribution channels for lubricating-cooling liquid, which ensures uniform and homogeneous lubrication by directing the liquid directly to the forging surface, reducing waste and the need for external spraying systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external spraying systems are used for lubrication, then the forging surface can be lubricated, but lubricant waste increases and surface coverage becomes inhomogeneous
Solution Approach 1:
The mould serves itself by incorporating internal feeding channels and distribution channels that deliver lubricating-cooling liquid directly to the forging surface from within the mould structure, eliminating the need for external spraying systems and achieving homogeneous surface coverage without lubricant waste
Solution Approach 2:
The patent uses a hydraulic system with feeding channels and distribution channels to deliver lubricating-cooling liquid through the mould structure, utilizing fluid pressure to ensure controlled and homogeneous distribution of the lubricant directly at the forging surface
2Reliability
If excessive lubricating-cooling liquid is used for lubrication, then the forging surface can be adequately lubricated, but thermal fatigue increases and maintenance frequency increases
Solution Approach 1:
The patent applies lubricating-cooling liquid locally and precisely where needed through distribution channels positioned at specific locations within the mould, rather than applying excessive liquid broadly, thereby providing adequate lubrication while minimizing thermal fatigue and extending equipment life
Solution Approach 2:
The internal channel system provides controlled delivery of lubricating-cooling liquid based on the actual needs of the forging surface, preventing excessive lubricant application that would cause thermal fatigue, and enabling better control over the lubrication process to extend mould longevity
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 solution minimizes lubricant waste, enhances surface coverage homogeneity, reduces maintenance frequency, and mitigates thermal fatigue, resulting in improved product quality and extended equipment life by optimizing lubrication within the mould.
Implementation Method 1
to increase the heat exchange, in the half-moulds it is also possible to provide for cooling channels in which water, which continuously removes heat, circulates
Implementation Method 2
another fundamental aspect of the hot forging processes relates to the lubrication of the mould, which usually occurs through a specific lubrication step carried out before the insertion of the billet between the half-moulds
Data Source
AI summary
A mould for hot forging includes a first half-mould and a second half-mould. The first and second half-moulds each include a mould holder having a recess and a die provided with an impression. The die is combined with the mould holder at the recess. At least one of the first half-mould and the second half-mould is provided with at least one feeding channel for a lubricating-cooling liquid, extending from an outer wall of the mould holder to the recess of the mould holder, and with a plurality of distribution channels for the lubricating-cooling liquid. At least one quota of the plurality of distribution channels includes distribution channels extending from a wall of the die facing the recess, to the impression. The at least one feeding channel and the distribution channels face at least one gap formed between the mould holder and the respective die at the recess.