Hot Forging Transfer Heating to Prevent Double-Barreling Defects
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Solution Overview
Problem
In hot die forging with Ni-based super heat-resistant alloys, the generation of double-barreling shaped forging defects occurs due to temperature variations during the transfer of materials, leading to reduced yield and increased manufacturing costs, especially when the die temperature is 950° C. or more.
Innovation Solution
A method involving a heated holding jig to maintain the material's surface temperature during transfer, with the jig heated between 50° C. lower and 100° C. higher than the material's heating temperature, and the die heated to 950 to 1100° C., to prevent temperature decrease and subsequent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the die temperature is increased to 950°C or more to reduce temperature difference with the material, then the workability of the material improves and the shape near the final shape is achieved, but double-barreling shaped forging defects occur due to temperature variations during transfer
Solution Approach 1:
The holding jig is preheated to a temperature between 50°C lower and 100°C higher than the material heating temperature before the material is transferred. This preliminary heating action ensures that when the material contacts the jig during transfer, temperature decrease is prevented, thereby avoiding double-barreling defects while maintaining the high die temperature needed for shape accuracy
Solution Approach 2:
A holding jig serves as an intermediary tool between the furnace and the die during material transfer. The jig is designed to be heated to appropriate temperatures and used to hold and transfer the material without causing temperature decrease, thus mediating the transfer process to prevent defects
2Reliability
If a heated holding jig is used to maintain material temperature during transfer, then temperature decrease is prevented and defects are avoided, but device complexity increases
Solution Approach 1:
The holding jig serves multiple functions: it holds the material during transfer, maintains material temperature through preheating, and prevents temperature decrease that would cause defects. By consolidating these functions into a single component, the system avoids needing multiple separate heating devices or complex temperature control systems
3Loss of substance
If isothermal forging is used to achieve shape near final shape with no inhomogeneous deformation, then material cost decreases, but die cost increases due to requirement of high-temperature strength
Solution Approach 1:
The invention changes the operating temperature parameter by using hot die forging at 950°C or more instead of isothermal forging. This parameter change allows the use of conventional die materials with sufficient strength at these temperatures, reducing die cost while the heated holding jig prevents defects to maintain material efficiency
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
Prevents the generation of double-barreling shaped forging defects while maintaining productivity, ensuring a higher yield and reducing manufacturing costs by maintaining consistent material temperature during the forging process.
Implementation Method 1
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
Implementation Method 2
a transfer step of transferring the material for hot forging onto the lower die by using the holding jig attached to a manipulator... to prevent temperature decrease
Implementation Method 3
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 die heating step of heating the upper die and the lower die to a heating temperature within a range of 950 to 1100° C.
Data Source
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.