Segmented Hot Forging Die with Nickel Alloy Layer
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Solution Overview
Problem
Existing hot forging die technologies face challenges in producing large-sized, high-quality forged products like aircraft jet engine disks and gas turbine disks due to high deformation loads and material wastage, leading to poor productivity and difficulty in achieving the desired shape.
Innovation Solution
A hot forging die is constructed by concentrically fitting and fastening multiple die pieces, with a columnar die piece at the center and outer ring-shaped pieces, using alloy tool steel and a nickel-base super heat-resistant alloy build-up layer to enhance strength and durability, allowing for efficient assembly and reduced material wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a monolithic material block is used to produce hot forging dies for large-sized forged products, then the die can withstand high deformation loads, but the material block weight exceeds 5 tons and requires a large-sized steel ingot with dissolution weight more than 10 tons
Solution Approach 1:
The die is divided into multiple die pieces (first die piece, second die piece, third die piece) that are assembled together to form the complete hot forging die. This segmentation allows the die to achieve the required strength for withstanding high deformation loads while reducing the weight of individual components and minimizing material wastage during manufacturing.
2Device complexity
If a monolithic material block is used to produce hot forging dies, then the die structure is simple, but many materials are scrapped during die-sinking resulting in poor productivity
Solution Approach 1:
The die structure is segmented into multiple independently manufacturable pieces that are assembled together. This approach reduces material wastage during die-sinking for each individual piece compared to processing a single large monolithic block, thereby improving productivity while maintaining the overall die structure through careful design of the segmented components.
Solution Approach 2:
The invention minimizes material discarding by optimizing the segmentation strategy and assembly process. The die pieces are designed and manufactured to reduce scrap during die-sinking operations, and the assembly process itself recovers the functional integrity of the complete die structure without requiring excessive material removal.
3Weight of stationary object
If multiple die pieces are assembled radially to reduce die weight, then the die pieces can move freely in the radial direction during forging, but the forging material invades into the gaps between moved die pieces making it difficult to achieve the desired shape
Solution Approach 1:
The die is segmented into multiple pieces arranged in a specific configuration (first die piece at the center, second die piece surrounding it, and third die piece on the outer periphery). This segmentation reduces die weight while the careful design of piece arrangement and movement constraints prevents material invasion into gaps, maintaining shape accuracy.
Solution Approach 2:
The die pieces are designed with controlled mobility during the forging process. The first, second, and third die pieces can move to accommodate material flow, but their movement is regulated to prevent excessive gap formation that would allow forging material to invade and compromise the desired product shape.
Data Source
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AI summary
Provided is an inexpensive hot forging die which allows a desired shape to be obtained even from a large-sized forging material. A hot forging die, for closed die hot forging of a material to be forged, includes a plurality of ring-shaped die pieces which are combined concentrically and fastened with each other, wherein an axial direction of the ring-shaped die pieces is identical with a pressing direction when the material is forged, and wherein a die face and a build-up layer of a nickel-base super heat-resistant alloy are formed at a part of the hot forging die, which is brought into contact with the material to be forged.