Modular Metal Block Forging with Hourglass Module Assembly
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Solution Overview
Problem
Existing methods for manufacturing large metal blocks are unreliable and inefficient, particularly for forgings over hundred tons, as they require high equipment standards and result in significant losses when weld joints fail, making one-time construction forming difficult and costly.
Innovation Solution
A modular metal construction forming method involving prefabricated blanks welded in pairs within a vacuum chamber, followed by upsetting deformation and heat preservation, repeated to form hourglass-shaped modules that are then further processed to create larger modules, allowing for controlled deformation and reduced surface tensile stress, ultimately forming a large metal block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If one-time construction forming method is used for large metal blocks, then manufacturing efficiency is improved, but reliability deteriorates due to high equipment requirements and huge losses when weld joints fail
Solution Approach 1:
The patent divides the large metal block construction into multiple modules (first modules, second modules, intermediate modules) that can be manufactured separately and then assembled. This segmentation allows each module to be produced with controlled requirements, reducing equipment constraints and enabling quality verification at each stage, thereby improving reliability while maintaining productivity.
2Ease of manufacture
If conventional forging method is used for large forgings, then manufacturing simplicity is maintained, but productivity deteriorates due to extremely difficult one-time construction forming for hundred-ton forgings
Solution Approach 1:
The construction process is divided into modular units that can be manufactured independently using conventional forging methods, then assembled through welding. This approach maintains the simplicity of conventional methods while improving productivity by allowing parallel manufacturing of multiple modules and reducing the burden on single equipment.
Solution Approach 2:
The patent prepares prefabricated blanks and modules in advance before final assembly. These pre-fabricated components can be manufactured, inspected, and prepared simultaneously, then assembled in a coordinated sequence, thereby improving overall productivity without complicating the manufacturing process.
3Ease of manufacture
If hourglass-shaped modules are used in construction, then manufacturing cost is reduced due to reduced pressure requirements, but device complexity increases due to specific shape requirements
Solution Approach 1:
The patent employs hourglass-shaped modules with asymmetric geometry that concentrates deformation at the interface positions during upsetting. This asymmetric design optimizes the stress distribution, reducing the peak pressure requirements and manufacturing costs, while the shape is achieved through standard forging processes.
Solution Approach 2:
The hourglass shape creates localized deformation zones at the interface positions of the modules. By concentrating the deformation in specific local areas rather than uniformly across the entire component, the required pressure is reduced, lowering manufacturing costs while the shape is formed using conventional forging equipment.
4Reliability
If multiple modules are assembled through welding, then reliability is improved through quality control of each module, but loss of time increases due to repeated welding and assembly operations
Solution Approach 1:
The patent prepares multiple modules and prefabricated blanks in advance before final assembly. These modules can be manufactured, inspected, and prepared simultaneously in parallel, then assembled in a coordinated sequence. This preliminary preparation reduces the actual assembly time and minimizes the impact of welding operations on the overall construction period.
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 enhances the reliability and efficiency of large metal block production by allowing for quality control of each module, reducing production time, and minimizing pressure requirements, thereby increasing yield and reducing production costs while avoiding surface tensile stress.
Implementation Method 1
vacuum electron beam welding is conducted
Implementation Method 2
within a vacuum chamber
Implementation Method 3
high-temperature diffusion bonding
Implementation Method 4
heating temperature is not less than 1200°C
Implementation Method 5
upsetting deformation
Implementation Method 6
height reduction of implementing upsetting deformation
Data Source
Figure 1
Figure 2a~2h
Figure 3(a)~3(i)
AI summary
The invention relates to a forming method for modular metal construction. According to the method, prefabricated blanks of large forgings are divided into multilevel modules to perform construction respectively based on the specification conditions, and a blank is finally prepared and is processed into a component or a part. The method is more reliable and controllable in construction quality. Each module can be subjected to flaw detection after being forged, so that the fact that the modules can be used after being qualified is guaranteed; and multiple pieces can be put into production, so that the construction period can be effectively guaranteed. The method can improve the yield of large metal construction forming.