Method for manufacture of forged piece with high hub portion having deep cavity by means of hot stamping

FIELD: technological processes.

SUBSTANCE: by means of preliminary hammer stamping, preliminary forged piece is produced with tapered hub piece. Then final forged piece is molded with tapered hub piece by stamping in trimming press with burr cutting and punching of deep cavity. Heights of hub portions in preliminary and final forged pieces are equal to each other. Angle of preliminary forged piece hub portion taper exceeds angle of final forged piece tapered hub portion cone. At that difference between volume of tapered cone that creates tapered hub portion of preliminary forged piece and volume of truncated taper that creates tapered hub portion of final forged piece, is equal to volume of punched deep cavity. Punching is done with expansion of preliminary forged piece hub portion.

EFFECT: higher quality of forged pieces and lower power inputs in their manufacture.

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The invention relates to the processing of metals by pressure and can be used in forging and stamping production during the manufacture of the universal unit: hammer forging - press cut forgings for details hubs, hub flanges, transitions, with the flange.

There is a method of forming the hammer forgings such as a tapered rod with flange - forged II group 3 subgroup (Forging and stamping: a Handbook. 4 so/Ed. tip: E.I. Semenov and others - M.: Mashinostroenie, 1986 - Vol.2. Hot stamping/Ed. by E.I., 1986. - 592). To obtain forging the necessary preliminary operations: broaching stud or landing flange. Forged stamped without cavity or has a small remote basting hole. A through hole to receive the subsequent machining, which leads to a large consumption of metal and high complexity processing.

There is a method of forming a bump on the press forgings with a blind or through hollow flange (V group 3 subgroup) by extruding a solid billet in a closed annular cavity (Forging and stamping: a Handbook. 4 so/Ed. tip: E.I. Semenov and others - M.: Mashinostroenie, 1986 - Vol.2. Hot stamping/Ed. by E.I., 1986. - 592). The disadvantage of this method is mnogovershinnoe (labor) forming, which determines the feasibility of the method only on the mechanical the ski and hydraulic presses.

A known method of manufacturing a hollow flange forgings (A.S. No. 1552460 "Method of making hollow flange forgings, including subsidence of the original piece to the diameter of the flange thickening in the floor of the semi-finished product, which is obtained subsequent stamping in the outdoor stamp with a height less than the height of permanently stamped forgings, formoobrazovanii on the next transition of the direct extrusion with simultaneous shaping of the flange. This semi-finished product should have the following geometrical parameters: hub length is not more than the length of the hub forgings, and the height of the flange thickening is not less than the height of the flange. Such a semi-finished product is subjected to a final deformation. The disadvantage of this method is the necessity of regulation of the parameters of the hub and flange portions of the semi-finished product, as well as the feasibility of the method only to the press.

A known method of manufacturing a hollow axisymmetric products (patent No. 1807914 "Method of making hollow articles"). Specially prepared blank is placed in the upper part of the matrix and carry out shaping (firmware) of the punch, a larger diameter which is equal to the smaller diameter of the matrix, or less. When this occurs, the combined extrusion shift (cej) of the metal under the punch and push it into the lower part of the cavity of the matrix is. The strain pattern and examples of technological transitions forming axisymmetric products using the FAC is available in Upitis. Combined extrusion shear / press-Forging production, 2005 - No. 3, s-28.

The disadvantages of this method are:

- the need for preliminary preparation of the original piece by calibration in the container, figure draught, closed die forging with calibration;

- quality forgings with a hollow hub is possible only in a narrow interval of correlation coefficient firmware (the ratio of the square cavity and a larger base procurement) and square side support surface of the workpiece.

Combined extrusion shift is implemented in the method of forming a tapered sleeve with flange (A.S. No. 532444 "Method of forming in a matrix conical sleeve with flange"). The method involves the extrusion of a back-pressure pre-mounted workpiece to receive the flange of the desired size, and then stitch the resulting billet flange, filling this metal spare part cone matrix. The matrix stack is pre-mounted workpiece, and under the influence of the punch, the metal billet is extruded in the tapered part of the matrix, having a slope equal to the slope forming, before receiving the flange of the desired size. For camcog the clearance angle of the bottom end and prevent bumps on the end use pusher with backpressure. After extrusion, the billet is placed in a matrix having a slope equal to the slope forming where her stitch punch, along with filling out the free part of the cone matrix. The excess volume of the workpiece when it is removed in the form of "notching" variable height.

The disadvantage of this method is the possibility of warping on the second transition metal stamping flange part forgings and not filling the corners of the cavity of the matrix of this transformation.

There is also known a method of hot stamping with firmware deep holes in high hub (A.S. No. 99012 "Method of hot stamping with firmware deep holes in high hub"), selected by the applicant as a prototype. According to this method, first, a final stamp on the hammer forgings in all its parts, except the hub, designed in the form of a set of metal, which is then permanently deform in a combined stamp on a mechanical press, where one stroke cut off the Burr and the stitch hole while forming the hub.

The disadvantage of the prototype is the possible buckling of the flange and the instability of tall size forgings due to inconsistent transitions stamping on the hub part:

- ability to influence at the firmware on the flange portion of the trim punch;

- ability to develop when flashing stage reverse issuing the-air traffic management;

- large forces and work strain.

The technical task of the invention is to improve the quality of hollow forgings high hub due to the stability of the size of the forgings in height and lack of distortion of the flange, as well as the reduction of energy consumption by the firmware on the trim press.

To achieve these objectives in the method of manufacturing forgings with high hub part having a deep cavity, hot stamping, including prior forgings with conical hub part by pre-hammer forging and shaping the final forging with conical hub part by stamping on the trim press with a cutting Burr and firmware deep cavity, according to the invention receive a preliminary forging with conical hub part, which has a height equal to the height of the hub part of the final forging, and the cone angle greater than the angle of the cone of the conical hub part of the final forging from the condition of equality of the difference between the volume of a truncated cone, forming a conical hub portion prior forgings, and the volume of a truncated cone, forming a conical hub portion of the final forging, the volume of drilled deep cavity, and the firmware mentioned deep cavity is performed with the distribution step is ERN part of the preliminary forging.

The preliminary forging with conical hub part, which has a height equal to the height of the hub part of the final forging, contributes to improving the quality of forgings due to the stability of tall size forgings.

The execution of the cone angle of hub part of the preliminary forging greater than the cone angle of the conical hub part of the final forging from the condition of equality of the difference between the volume of a truncated cone, forming a conical hub portion of the preliminary forging, and the volume of a truncated cone, forming a conical hub portion of the final forging, the volume of drilled deep cavity, and firmware deep cavity with the distribution hub part of the preliminary forging also contributes to improving the quality of forgings by eliminating the formation of backward extrusion that provides stability tall size forgings and no warping of the flange. In addition, due to the difference in taper when flashing cavity is provided over the metal only in the radial direction, which, in turn, helps to reduce the efforts of the firmware.

Patent research did not reveal ways, characterized by the claimed combination of features, therefore, we can assume that this method is correspond to the criterion "novelty".

Using a combination of distinctive features is also not known, which indicates the criterion of "inventive step".

In addition, the proposed method can be used on an industrial scale and will find application, in particular, forging and stamping production in the manufacture of stamping on the hammer and trim press forgings for details hubs, hub flanges, i.e. characterized by the criterion of "industrial applicability".

The essence of the proposed technical solution is illustrated by diagrams and photographs, in which figure 1 shows a diagram of transitions stamping parts "hub", figure 2 shows a diagram of shape variation with a hammer stamping, where a is the original billet, b - preliminary forging, d successive stages firmware cavity. The essence of the proposed technical solution is illustrated by photographs, where photo 1 experienced forging flange 2501-12-248, photo 2 - a pilot batch of forgings "flange".

The inventive method is carried out as follows.

Heated to forging temperature of a piece billet is subjected to drawing (procrastination) the twang in the stream Molotov stamp (figure 1), and then punched open stream prior forgings equal to the final height with finalized flange and basting for firmware (figure 1; figb). While cone angle of the conical hub portion of the preliminary forging more than the final. Then trim the press in sequential stamp is cutting scrap and deep firmware cavity (figure 1). The final shape of the hub there is a deep firmware with the distribution, while the metal of the axial zone of the semi-finished product is pressed into the cavity formed by the difference of taper hub part of the preliminary and final forging (figure 2 b-d). This ensures equal to the difference between the volume of a truncated cone, forming a conical hub portion of the preliminary forging, and the volume of a truncated cone, forming a conical hub portion of the final forging, the volume of drilled deep cavity.

On the last position of the trim punch is punching thickened jumper (figure 1).

In January 2006, in the production conditions of the Forge plant of JSC "Kurgan machine-building plant" was tested the technology of stamping on the forging flange 2501-12-248 (photo 1).

The source data to the design of the final forging:

GCR=Gd·p- estimated weight of forgings,

where Gd=9,4 kg - the mass of the part;

Top=1.5 to the estimated coefficient;

GCR=9,4·1,5=14,1 kg

Accuracy class - T4 (the deformation is carried out on the stamping hammer, open the stamp when using plamenov the heat).

Group steel - M2 (mass fraction of carbon in the steel more than 0,35% to 0.65%).

Degree of difficulty - C3, as

GCR/Gf=0,19,

where Gf- weight geometric shape that fits the shape forgings. This figure is a cylinder with a diameter equal to the diameter of the flange, and a height equal to the height of forgings. Gf=73 kg

The configuration of the parting surface of the stamp - N (flat).

The original index - 16, table 2 GOST 7505-89, based on the weight of forgings, precision class T4, group M2 steel, complexity C3.

Preliminary forging is obtained by stamping operations in the open Molotov stamp. Design preliminary forging differs from the final forging dimensions of the hub part and the absence of a deep cavity.

Then to find the angle of the taper hub part of the preliminary forging calculate the volume of a truncated cone V1and then find the radius of its smaller base, taking the height of the conical hub portion of the preliminary forging equal to the height of the conical hub part of the final forging.

Using the progress of design and technological documentation were designed and manufactured a hammer stamp (AEG 1300-7673) PVSM 5 t and trim combo stamp (AEG 1425-6709) on the trim press with the force of 6.3 MN.

In experienced the th party was stamped 9 forgings, in General, the relevant drawing forgings and technical requirements (photo 2).

A method of manufacturing forgings with high hub part having a deep cavity, hot stamping, including prior forgings with conical hub part by pre-hammer forging and shaping the final forging with conical hub part by stamping on the trim press with a cutting Burr and firmware deep cavity, characterized in that receiving pre-forging with conical hub part, which has a height equal to the height of the hub part of the final forging, and the cone angle greater than the angle of the cone of the conical hub part of the final forging from the condition of equality of the difference between the volume of a truncated cone, forming a conical hub portion of the preliminary forging, and the volume of a truncated cone forming a conical hub portion of the final forging, the volume of drilled deep cavity, and the firmware mentioned deep cavity is performed with the hand wheel parts prior forgings.



 

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