Hot Forging Transfer Heating to Prevent Double-Barreling
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Solution Overview
Problem
In hot die forging, the generation of double-barreling shaped forging defects occurs due to temperature variations between the material and die, leading to reduced yield and increased manufacturing costs, especially when using Ni-based super heat-resistant alloys at high die temperatures.
Innovation Solution
A method involving a heated holding jig to maintain the material's surface temperature during transfer, with both the upper and lower dies made of Ni-based super heat-resistant alloys, heated to a temperature range of 950 to 1100°C, ensuring the material's surface temperature remains higher than the die's surface temperature, thereby preventing double-barreling defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the die temperature is lowered to improve die life and high-temperature strength, then die life is improved, but the material surface temperature decreases due to die chilling, causing double-barreling shaped forging defects
Solution Approach 1:
The material surface is heated in advance before contact with the die, ensuring that even when contacting a relatively cool die, the material maintains sufficient temperature to prevent double-barreling defects while allowing the die to be at a temperature that preserves die life
2Manufacturing precision
If the die temperature is raised to prevent double-barreling defects, then manufacturing precision is improved, but die life decreases due to high-temperature exposure
Solution Approach 1:
The material surface is pre-heated to a temperature higher than the die temperature, allowing the use of a die at moderate temperature (which preserves die life) while ensuring the material maintains sufficient temperature during forming to prevent defects
3Manufacturing precision
If isothermal forging is used to prevent double-barreling defects, then manufacturing precision is improved, but equipment cost and operation cost increase
Solution Approach 1:
Instead of heating the entire die to high temperature (isothermal forging), only the material surface that contacts the die is pre-heated to a higher temperature, creating a localized temperature difference that prevents defects while allowing the bulk die to remain at a lower, more economical temperature
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 method effectively prevents the generation of double-barreling shaped forging defects while maintaining productivity, enhancing the quality and yield of the hot forged material.
Implementation Method 1
a transfer step of transferring the material for hot forging onto the lower die by using the holding jig attached to a manipulator after the completion of the raw material heating step, the jig heating step, and the die heating step, and placing the material for hot forging on the lower die heated in the die heating step, a surface temperature of the material for hot forging being higher than a surface temperature of the die
Implementation Method 2
a jig heating step of heating a holding jig for holding the material for hot forging within a temperature range of 50°C lower than and 100°C higher than the heating temperature of the material for hot forging
Data Source
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AI summary
Provided is a method for producing a hot forged material capable of preventing the generation of double-barreling shaped forging defects. A method for producing a hot forged material, wherein both an upper die and a lower die are made of Ni-based super heat-resistant alloy, and a material for hot forging is pressed by the lower die and the upper die in the air to form the hot forged material, the method comprising: a raw material heating step of heating the material for hot forging in a furnace to a heating temperature within a range of 1000 to 1150°C; a jig heating step of heating a holding jig for holding the material for hot forging within a temperature range of 50°C lower than and 100°C higher than the heating temperature of the material for hot forging; a die heating step of heating the upper die and the lower die to a heating temperature within a range of 950 to 1100°C; and a transferring step of transferring the material for hot forging onto the lower die by using the holding jig attached to a manipulator after the completion of the raw material heating step, the jig heating step, and the die heating step.