A method of manufacturing a hollow flange forgings

 

The invention relates to the processing of metals by pressure and can be used in the manufacture of hollow flange forgings by forging. A method of manufacturing a hollow flange forgings includes draught of the original piece, the formation of the outdoor stamp hollow semi-finished product with the formation of the flange thickening and hub with a jumper and final forging open die. The formation of the semi-finished product is carried out in two stages. At the first stage to form the flange thickness, cavity and solid hub part. The depth of the cavity is equal to 0.5-2.5 height flange thickness semi-finished product. The volume of the hub part 0.9-1.1 times the volume of hub portion formed in the second step of forming the semi-finished product. In the second stage reverse extrusion form the hub. In the expanding technological possibilities of the method of manufacturing a hollow flange forgings. 7 C. p. F.-ly, 2 Il.

The invention relates to the processing of metals by pressure and can be used in the manufacture of hollow flange forgings by forging.

A known method of manufacturing a hollow flange forgings (patent 1552460, CL 21 To 21/00, 1993), including a draft of the workpiece to a diameter, ray height at least the height of permanently stamped forgings, this increases the height of the semi-finished product by moving the metal extruded from the Central part of the barrel in the hub, the length of which is determined by the formula: Lc > lc > T + Ro + R, where Lc is the length of the hub forgings; line with an - hub length of the material; T is the thickness of the bottom of the jumper; Ro is the radius of the pair of jumpers from the side surface of the cavity forgings; R is the radius of the mating flange with the side surface of the hub, and the height of the flange thickening determined by the formula: NF <h <1,5(DF - Do), where NF is the height of the flange thickening forgings; h - height flange thickening of the material;
DF - diameter flange thickening of the material;
Do is the diameter of the hollow forgings.

The above method has limited technological capabilities. It is designed to produce forgings with average flanges, when the ratio of the diameter of the flange thickening finally stamped forgings DF to the diameter of the hub is permanently stamped forgings Dc is in the range of 1.5 to 2.5.

The method does not allow to produce forgings with small flange with respect to the diameter of the flange thickening finally stamped forgings DF to the diameter of the hub is permanently stamped forgings Dc less than 1.5.

The method does not allow the floor is in - hub diameter internal.

Attempts to implement it for such forgings lead to thinning of the walls up to rupture.

A known method of manufacturing a hollow flange forgings (patent 2169632, CL 21 To 23/04, 2000), including a draft of the original piece, forming a hollow semi-finished product with the formation of the hub with a jumper by moving metal draft towards the free surface of the flange thickening to the size in terms of not exceeding the dimensions of the flange in the plan are permanently stamped forgings and cavity semi depth in range (0,8-1,2) from the depth of the cavity is permanently stamped forgings, final forging direct extrusion with simultaneous formation of the flange.

The above method has limited technological capabilities. It is designed to produce forgings with developed flanges, when the ratio of the diameter of the flange thickening finally stamped forgings DF to the diameter of the hub is permanently stamped forgings DC exceeds 2.0 to 2.5.

The method does not allow to produce forgings with small flange with respect to the diameter of the flange thickening finally stamped forgings DF to the diameter of the hub is permanently stamped forgings D the mi hub part.

The task: to develop a method of manufacturing a hollow flange forgings with broader technological capacity to obtain forgings with small flange, long hub and thin-walled hub portion forgings.

The problem is solved due to the fact that in the method of manufacturing a hollow flange forgings, including draught of the original piece, the formation of the outdoor stamp hollow semi-finished product with the formation of the flange thickening and hub with a jumper by moving the metal from the Central part, the final forging open die, forming semi-finished product is carried out in two phases: in the first form the flange thickness, the cavity depth of 0,5-2,5 height flange thickness semi-finished product and a solid hub part by volume of 0.9-1.1 times the volume of hub portion formed in the second step of forming the semi-finished product, and at the second stage reverse extrusion form the hub.

At the first stage of the formation of the semi-finished product hub receive draft and flange thickness distribution and draught.

At the first stage of the formation of the semi-finished product hub receive direct extrusion, and the flange thickness distribution.

At first this is Oh.

At the first stage of the prefabricated form with the displacement of the metal in the scrap.

In the first stage, the semi-finished form without displacement of the metal in the scrap.

At the first stage of the formation of semi-finished flange thickening receive a volume equal to 0.9-1.2 volume flange permanently stamped forgings.

Final stamping is conducted at the stamp with compensator, displacing the metal in the scrap and the Central part of the bridge.

The formation of the semi-finished product in two stages permits the first stage to collect the required amount of metal for the subsequent forming of the flange in the final stream and stateroute the amount of metal that the second stage will go on to form the hub.

In this case, the forging is formed sequentially (elementwise). For its high-quality design is not necessary to distill the metal from other places of procurement spending additional energy and, consequently, increasing the required force of deformation, which affects the resistance of die tooling.

The depth of the cavity depending on the configuration and sizes of forgings limit value of 0.5-2.5 height flange thickness semi-finished product.

When performing cavity is less than 0.5 of the height of the flange Tolstiak. As a result, the second stage of the formation of the semi-finished product possible distortion of the semifinished product and the formation of folds. When the lower limit of 0.5 is achieved best results in ravnoudalennostj (symmetry) of the semifinished product. For such a cavity of the desired relatively short punch, which has a higher hardness.

When performing oral 2.5 height flange thickening in the deformation process occurs first separation of the metal from the matrix in the area of the flange, and then the formation of folds in podunavac area. It is also possible the formation of the defect within the hub.

Solid hub portion at the first stage to form a volume of 0.9-1.1 times the volume of hub portion formed in the second step of forming the semi-finished product.

These possible limits of fluctuations of volume allow to obtain high-quality forgings with the inevitable fluctuations of process parameters stamping (temperature, friction, wear clichés, bias adjustment and so on). Beyond these limits entails the subsequent transitions stamping unfounded moving metal from one side of the semi-finished product to another (the hub flange). This increases the energy-power parameters of the process and over cnie special cases of the formation of the flange and hub parts forgings: draft, hand, squeezing. At the first stage of the formation of the semi-finished product possible deformation with displacement of the metal in the scrap or non-preemptive.

At the first stage of the formation of semi-finished flange thickening receive a volume equal to 0.9-1.2 volume flange permanently stamped forgings.

Limit 0,9 allows, if necessary, to place in the final stamping part metal hub portion of the flange part. This allows to compensate the fluctuation of the volume of the hub part of the first stage associated with die wear and fluctuations of process parameters stamping (temperature, friction conditions, adjustment and so on). At a lower limit excessive expiration of the metal of the hub part forgings and education clamp under the flange part in the final stamping. Limit of 1.2 allows you to fully compensate for inaccuracies segments of the original piece, tool wear and process fluctuations stamping process. Great value limit unreasonably the excess metal that is displaced during the final stamping Burr, and increase energy-power parameters of the stamping.

Comparative analysis tablemodelliste from the prototype.

In the prototype of the semi-finished product is formed at one transition (phase).

In the proposed method, the formation of the semi-finished product is carried out in two stages. This regulates the process of gradual deformation: in the first stage to form the flange thickness, the cavity depth of 0,5-2,5 height flange thickness semi-finished product, and a solid hub part by volume of 0.9-1.1 times the volume of hub portion formed in the second step of forming the semi-finished product, and at the second stage reverse extrusion form the hub.

In the prototype regulate the depth of the cavity of the semi-finished product in relation to the depth of the cavity is permanently stamped forgings.

In the proposed method, regulate the cavity of the semi-finished product of the first stage relative to the height flange thickness semi-finished product, thus we set the parameters of the deformation zone of the second stage of the formation of the semi-finished product.

In the prototype the formation of the flange thickness semi-finished product is performed by the draft.

In the proposed method, the flange thickness of the semi-finished product can be performed by hand, and draft or by hand.

These distinctive features provide the ability to produce forging with small flanges and thin walls stupichnoye evidence patents and scientific and technical information revealed no new significant features of the present invention according to their functional purpose. Thus, the proposed solution meets the criterion of "inventive step".

In Fig. 1 presents technological transitions stamping of Fig.2 - the end of the deformation process upset billets, semi-finished product of the first stage, the intermediate product of the second stage and finally stamped forgings.

A method of manufacturing a hollow flange forgings is implemented as follows.

Monotonous forgings get a few transitions, for example, four, in which the source of the workpiece 1, obtained from a rod, rebuff, receiving the workpiece 2, then form a semi-finished product in two stages, receiving consistently semi-finished product of the first stage 3 and the semi-finished product of the second stage 4, then, by deforming the semi-finished product 4, get permanently stamped forgings 5.

The source of the workpiece 1, obtained from a rod, rebuff between the inserts 6 and 7 (see Fig.2) and receive the workpiece 2. Upset the workpiece 2 is installed in the cavity of the matrix 8. When the movement of the press slide down the punch 9 deforms upset the workpiece 2: forms potery removed from the punch 9 ejector 10 or extracted from the matrix 8 ejector 11. The resulting intermediate product 3 is installed in the plate 12 and is subjected to deformation by the punch 13, the result is a semi-finished product of the second stage 4, which is removed from the punch 13 ejector 14 or extracted from the matrix 12 of the ejector 15. The obtained semi-finished product 4 is installed in the matrix 16 and is subjected to deformation by the punch 17, the result is finally stamped forgings 5. Finally stamped forgings 5 is removed from the matrix 16 of the ejector 18 or removed from the punch 17 insert-a stripper 19.

A specific example of a hollow flange forgings details "Sleeve" made of steel 20 GOST 4543-71.

The original billet with a diameter of 75 mm and a height of 110 mm is heated in an induction heater to forging temperature, is fed into the heat punching stamp press 4000 kN in the first position stamping, rebuff to obtain a sphere of diameter 100 mm is Mounted billet shift to the next stream and form a flange thickness diameter 120,8 mm, height 25 mm, the cavity depth of 48.5 mm and a diameter of 83.6 mm, the hub portion of the semi-diameter of 104.5 mm, the resulting intermediate product of the first phase shift to the next stream and backward extrusion receive the semi-finished product with the diameter of the flange is punched forgings diameter flange part of the level of 121.8 mm, the diameter of the hub part 105,4 mm and a diameter of cavity 86,4 mm

Compared with the prototype of the proposed method for the manufacture of hollow flange forgings has greater technological capacity to obtain forgings with small flanges and thin-walled hub portion.


Claims

1. A method of manufacturing a hollow flange forgings, including draught of the original piece, the formation of the outdoor stamp hollow semi-finished product with the formation of the flange thickening and hub with a jumper by moving the metal from the Central part, and the final forging open die, characterized in that the formation of a hollow semi-finished product is carried out in two stages, the first of which form the flange thickness, the cavity depth of 0,5-2,5 height flange thickness semi-finished product and a solid hub part by volume of 0.9-1.1 times the volume of hub portion formed at the second stage of formation of semi-finished products and mentioned on second stage reverse extrusion form the hub.

2. The method according to p. 1, characterized in that the first stage in the formation of hollow semi solid hub portion to receive the draft, and flange with which arikata solid hub portion to receive a direct extrusion, and flange thickness - distribution.

4. The method according to p. 1, characterized in that the first stage in the formation of hollow semi solid hub portion to receive a direct extrusion, and the flange thickness - distribution and draught.

5. The method according to p. 1, characterized in that the first stage hollow prefabricated form with the displacement of the metal in the scrap.

6. The method according to p. 1, characterized in that the first stage hollow prefabricated form without displacement of the metal in the scrap.

7. The method according to p. 1, characterized in that the first stage in the formation of a hollow semi-finished flange thickening receive a volume equal to 0.9-1.2 volume flange permanently stamped forgings.

8. The method according to p. 1, characterized in that the final stamping is conducted at the stamp with the compensator and the displacement of the metal in the scrap and the Central part of the bridge.

 

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