Method for making ring-like cone gear wheel forged pieces

FIELD: plastic working of metals, namely forging production, manufacture of forged pieces of ring-like cone gear wheels with diameter 638 mm and with wide massive rim.

SUBSTANCE: method comprises steps of preliminarily upsetting initial blank with diameter 250 mm and length 335 mm; then subjecting upset blank to non-complete open broaching and its further die forging. All operations are realized in the same die set. Preliminary upsetting is performed on flat striker with diameter 350 mm till achieving diameter of upset blank equal to said value. Striker is arranged in central portion of die set impression before broaching and after broaching it is removed. Non-complete open broaching of upset blank is realized by means of detachable cone broach with mounting land having diameter 270 mm.

EFFECT: improved quality of produced forged pieces.

8 dwg, 1 ex

 

The invention relates to the processing of metals by pressure and can be used in forging and stamping production in the manufacture of forgings for parts with massive wide rim with a diameter of 400...600 mm type gears, disks, rings and flanges.

The known method an open cylindrical billets by drift-pin strengthening, having a conical side surface [A.S. 518262 USSR MCI B21J 5/10; VK 1/32. The way of the open cylindrical billets]. The obtained semi-finished product can be used for subsequent die forging ring of forging large dimensions. The disadvantage of this method is the high complexity of the full cycle of processing.

There is a method of manufacturing the same stamp jewelry type rings with a massive rim by pre-incomplete open firmware original piece tapered drift-pin strengthening and further by forging semi-finished product (prototype) [A.S. 1000151 the USSR, MKI UK 1/28; B21J 5/02. The method of manufacturing products of the type rings with a massive rim]. In the manufacture of rings with a high and massive rim at the final stage firmware produce forced to fold in the peripheral part of the semi-finished product in the annular cavity engraving stamp and giving the metal a predominantly axial direction of the flow, and before by forging remove the drift-pin strengthening of the stamp.

The main is Dostatok known way - applicability for the item high ring forgings, characterized predominantly axial (vertical) orientation of the longest dimension of the cross section of the rim [Grigoriev GD, Kaplunov astray freight, Felde A.A., Zuev S. p. Method of forming ring products and tools for its implementation. // Die forging production. 1991, No. 2. - P.30-32]. In addition, if the firmware on a tapered drift-pin strengthening is uneven radial metal flow due to the presence of the original piece angled ends (figure 1), and the probability of non-axial insertion of the blank on the drift-pin strengthening and the impossibility of its recovery flashing process due to the early implementation of the drift-pin strengthening in the workpiece (figure 2, left part). Due to non-uniform metal flow when screwing the peripheral area of the workpiece formed by the undercut on the inner surface of the wall of the semi-finished product (figure 2, right part), which in the final stamping often leads to defect "clip" (figure 3). This defect formation increases with the manufacturer on this method of ring forgings with massive wide rim.

An object of the invention is to improve the quality and expand the range annular forging bevel gears produced in this way, by changing the nature of the formation of the semi-finished product by creating bol is e uniform and intense metal flow in the radial direction.

The goal of the project is achieved in that in the method of forming annular forging bevel gears with a diameter of 638 mm carry out a preliminary draft of the original piece with a diameter of 250 mm and a length of 335 mm, incomplete open firmware upset procurement and subsequent die forging, which is carried out in the same stamp, in this pre-draft exercise on a flat striker, having a diameter of 350 mm, until the diameter of the upset billet specified diameter flat striker before the firmware is placed in the Central part of the stream of the stamp, and after flashing is removed from the stamp and incomplete open firmware upset procurement exercise removable tapered drift-pin strengthening installation a platform having a diameter of 270 mm

Thanks to the introduction of this sign, you receive a new property is more uniform and intense metal flow in the radial direction with successive draft and incomplete open firmware that provides the redistribution of mass of the workpiece in accordance with product configuration, eliminates the formation of the undercut on the semi-finished product and the defect "clip" on the annular forgings with a wide rim. This allows us to conclude that this solution meets the criterion of "inventive step".

The essence of izopet the deposits is illustrated by drawings, where figure 4 shows the stamp and the original workpiece prior deformation on the flat firing (left part) and in the final stage of deformation (right part); figure 5 - the beginning (left side) and the end of the pre-deformation upset billet tapered drift-pin strengthening (right side); 6 - the beginning of die forging semi-finished product in the stream of stamp (left part) and the end of die forging (right side); 7 semi - finished forgings; Fig - finished forgings.

The method is as follows.

Use the stamp, consisting of the upper block 1 and the lower block 2. On the surfaces of the collision blocks executed work streams (engraving) stamp.

When raised, the top of unit 1 (figure 4) on the lower block 2 in its Central cavity set flat removable head 3. On the hammer 3 coaxially set the workpiece 4. By lowering the upper block 1 (done working stroke of equipment) is sediment blanks. When reaching the preset sizes upset billet (diameter striker D) the upper unit 1 is raised to its original position. The workpiece is lifted in the Creek stamp on the striker. In a known manner, for example mites, and the firing pin 3 is extracted from the stream of the stamp.

At the raised upper block 1 (figure 5) on the lower block 2 in its Central cavity set conical removable drift-pin strengthening 5 with a diameter of mounting pads 270 mm At the ushkanii upper block 1 (done working stroke of equipment) is incomplete open firmware, accompanied by draught and billet in the direction of further increasing its diameter. In the initial period of the second transition is dominated sediment with ill-defined implementation of the drift-pin strengthening, which provides the possibility of re-alignment with him workpiece and thereby improves the uniformity of the subsequent metal flow. Decreasing the thickness of the metal layer between the plane of the Creek upper block 1 and the end of the 5 drift-pin strengthening of the meridional cross-section of drilled billet takes a Cup-shaped appearance with a predominantly radial orientation of the largest dimension of the cross section of the peripheral part thereof. The final stage of the open firmware is in the absence of intensive wrapping metal into the cavity of the die and a uniform distribution of mass of the intermediate workpiece in accordance with the form of ring forgings in the plan.

When reaching the specified dimensions of the intermediate billet upper unit 1 is raised to its original position. The workpiece 4 is lifted in the stream of the stamp above the drift-pin strengthening. In a known manner, for example mites, the drift-pin strengthening 5 is extracted from the stream of the stamp. The workpiece (product) 4 again immersed in the stream (6). Produce die forging intermediate pieces to the size of the finished forging, with the recess on the outlining of the stream bottom block serves as a compensator metal parts, Wiesn is imago through internal blainy bridge in the final shaping of the product. Stamped forgings extracted from the stream of the stamp. The drift-pin strengthening 3 is again installed on the outlining of the lower block 2.

The method allows to obtain the annular forgings with massive wide rim on one universal stamping machine. There is no need the use of special dies and equipment for pre-shaping of the workpiece. Amount of pre-production is reduced not less than 2 times.

The example of the industrial tests.

The method was tested in the manufacture of forgings "bevel gear" (D) diameter 638 mm of steel 12HN3A, weight 115 kg on the machine: stamping hammer Ect press the trim force of 10 MN. Stream forging stamp AEG 1300-7470 had a ring cavity with the outer and inner diameters, respectively 647 mm and 312 mm Flat removable drift-pin strengthening performed with a diameter of 350 mm and a height of 59 mm Conical removable drift-pin strengthening diameter of 420 mm and a height of 69 mm had the installation area with a diameter of 270 mm installed in the stream removable flat firing deformed the original piece with a diameter of 250 mm and a length of 335 mm On the first transition was carried out (4 stroke) free of sediment workpieces up to a diameter approximately equal to the diameter of planar drift-pin strengthening. When this is mounted to the height 167 mm billet had a fairly uniform shape in plan. Upon reaching the specified size of the OS is part of the preform was removed from the stamp, remove flat drift-pin strengthening, has established a tapered drift-pin strengthening and put on it is mounted the workpiece. The second transition was performed (5 hits) incomplete open firmware upset billet. Here in the initial period was dominated by the deformation of the draft, which helped to restore the alignment of the workpiece and the drift-pin strengthening between the beats. After reaching the peripheral part of the semi-finished high-rise rate of 100 mm more intensively happened firmware, followed by further radial distribution. Upon reaching the diameter of the semi-finished product, is approximately equal to the diameter of the stream (622 mm), it was removed from the stamp was removed tapered drift-pin strengthening and put the cake mix into the stream. The shape and size of the semi-finished product (7) corresponded to the cavity size of the stream and the mass distribution of the elements of the forgings. The result of the deformation of the workpiece in a die (7 hits) received a complete forging with overflow and jumper, which was then moved to the trim press (Fig).

The results of the technical inspection revealed no defects stamping and compliance forgings requirements for acceptance. Developed technology for mass production of forgings "bevel gear".

The use of the proposed method of stamping for the manufacture of forgings such rings has the following advantages sravnenie is with prototype:

- possibility of making annular forgings with massive wide rim;

- elimination of risk education stamping defect in the form of local or ring "clip".

The method of forming annular forging bevel gears with a diameter of 638 mm, characterized by the fact that carry out a preliminary draft of the original piece with a diameter of 250 mm and a length of 335 mm, incomplete open firmware upset procurement and subsequent die forging, which is carried out in the same stamp, in this pre-draft exercise on a flat striker, having a diameter of 350 mm, until the diameter of the upset billet specified diameter flat striker before the firmware is placed in the Central part of the stream of the stamp, and after flashing is removed from the stamp and incomplete open firmware upset procurement exercise removable tapered drift-pin strengthening an installation space having diameter 270 mm



 

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The invention relates to the field of metal forming

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