Radial Forging With Coaxial Torque Motor for Core Recrystallization
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Solution Overview
Problem
Existing forging technologies face challenges in uniformly deforming cast forging blocks to prevent crack formation in the surface area while achieving sufficient recrystallization in the core area, particularly with large bite ratios.
Innovation Solution
A forging device with a torque motor-driven eccentric shaft and hydraulic cylinders, allowing for controlled deformation through radial forging with high stroke frequency and low stroke length, combined with hydraulic actuation for uniform deformation and recrystallization, minimizing local load variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large bite ratio is used to achieve sufficient core forming and pore reduction, then the structural improvement of the forging block is improved, but significant differences in deformation degree arise over the pressed length, leading to crack formation in the surface area
Solution Approach 1:
The forging process is segmented into multiple passes with decreasing bite ratios. The first pass uses a large bite ratio for core forming, followed by subsequent passes with progressively smaller bite ratios to uniformly deform the surface areas, thereby preventing crack formation while achieving structural improvement
Solution Approach 2:
The first forging pass performs preliminary core forming with a large bite ratio to address the central pore reduction requirement. Subsequent passes then address the surface deformation uniformity issue, effectively separating the core forming function from the surface finishing function across multiple sequential operations
2Object-affected harmful factors
If a small bite ratio is used to avoid surface cracking, then crack formation is reduced, but core forming and pore reduction in the forging block become insufficient
Solution Approach 1:
The forging process is divided into multiple passes where the first pass uses a large bite ratio for core forming and subsequent passes use smaller bite ratios for surface deformation. This segmentation allows each pass to specialize in one function, ensuring both core quality and surface integrity are achieved
Solution Approach 2:
The forging process employs periodic action through multiple sequential passes with varying bite ratios. The bite ratio is periodically reduced across passes, allowing the system to alternately focus on core forming and surface deformation, thereby achieving both objectives over time
3Manufacturing precision
If the outer punch part is decoupled from the eccentric drive to enable press forging with high bite ratio, then core forming is improved, but the device complexity increases due to additional decoupling mechanisms
Solution Approach 1:
The drive system is designed to be dynamic, allowing the outer punch part to be selectively coupled or decoupled from the eccentric drive based on the required forging mode. This dynamic reconfiguration enables the system to switch between radial forging and press forging operations without requiring separate dedicated systems for each mode
4Object-affected harmful factors
If radial forging with high stroke frequency and small bite ratio is used, then surface deformation uniformity is improved, but core forming and pore reduction become insufficient
Solution Approach 1:
The forging process is segmented into passes with different bite ratio characteristics. Early passes use larger bite ratios for core forming while later passes use smaller bite ratios for surface deformation uniformity, with the sequence optimized to achieve both core quality and surface integrity
Solution Approach 2:
Core forming is performed as a preliminary action in the first pass with a large bite ratio, establishing the necessary structural improvement in the forging block core. Subsequent passes then focus on achieving uniform surface deformation, effectively sequencing operations to address different requirements at appropriate times
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
Ensures uniform deformation and recrystallization across the pressed length of the forging saddle, preventing crack formation in the surface area and enabling effective structural improvement down to the core of the forging block.
Implementation Method 1
the inner punch part, which holds a forging tool, is drive-connected to the outer punch part by a hydraulic cylinder
Implementation Method 2
a torque motor designed as an internal rotor, coaxial with the eccentric shaft, is provided as the electric motor
Implementation Method 3
an eccentric drive which can drive the outer die part and whose eccentric shaft is connected to an electric motor via a coupling
Data Source
Figure 1~2
Figure 3
AI summary
A forging device for hot forming a cast forging block (1) is described, comprising radially guided forging dies (5), each having two die parts (7, 8) that can be displaced radially relative to each other, the inner die part (7) carrying a forging tool (2) being connected to the other outer die part (8) by means of a hydraulic cylinder (9), an eccentric drive (14) which drives the outer die part (8), the eccentric shaft (15) of which is connected to an electric motor via a coupling (23), and a pump (28) driven by the electric motor for supplying pressure to the hydraulic cylinder (9) between the inner and outer die parts (7, 8).In order to create advantageous design conditions, it is proposed that an electric motor be a torque motor (19) designed as an internal rotor, coaxial to the eccentric shaft (15), the rotor (20) of which is rotatably mounted on the eccentric shaft (15) or an eccentric shaft extension (21) following a drive flange (22) of the eccentric shaft (15), and that the coupling (23) is arranged between the rotor (20) and the drive flange (22).