CN101648253A - Die design method and forming process for enhancing quality of semi-solid forge pieces - Google Patents
Die design method and forming process for enhancing quality of semi-solid forge pieces Download PDFInfo
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Abstract
The invention belongs to the field of semi-solid forming technology, relating to a die design method and a forming process for enhancing the quality of semi-solid forge pieces. The invention is characterized in that a circular flange is taken as a study object; flow of blank keeps constant in each radius of the flange with a trapezoidal cross-section in an inclined angle of 10 to 20 DEG when forming; when the radial filling speed of the blank is Vr, the maximum outside diameter of the flange is R, the thickness of the flange at a position with the maximum outside diameter of R is h, wherein his larger than 5 mm and smaller than 7 mm; the thickness of the flange at the position with the radius of r is H(r), wherein r is larger than 0 and smaller than R, and the thickness H(r) meets the identity of flow front edge area; the radial filling speed of the blank is carried out by adjusting the forming speed of a pressing machine and the semi-solid temperature of the blank, the radial fillingspeed forms a constant which has nothing to do with the size of the radius, in this way, the flow front edge area multiplied by the radial filling speed makes the constant, i.e. the radial volume flow is still equal. In the invention, semi-solid slurry realizes filling with equal volume flow in the forming process, and the problems of cracking and non-closure of flow front edge in the semi-solidthixotropy forging forming process are solved.
Description
Technical field
The invention belongs to the semi-solid state forming technique field, a kind of die design method and forming technology that improves quality of semi-solid forge pieces particularly is provided.
Background technology
Progress of modern technology improves day by day to the requirement of Materials Science and Engineering technology, develop the novel high-performance structural material with and advanced short flow process process technology become vast high-tech enterprise and needed the urgent problem that solves, this phenomenon embodies more obviously in fields such as automobile, Aero-Space, boats and ships.At present, high-accuracy high-quality complex structural member uses the method for machining to be made usually.Because this traditional machining process has long, more high defectives of production cost of process-cycle, explore for a long time short flow process, nearly end form high-quality structural member production method, and can become a kind of exigence from experimentally preparing the high-quality structural member and studying its performance.How to find a kind of manufacturing process cleverly to become one of numerous scientists and engineers and have creative and challenging work.At present, the main bottleneck of problem is the material forming technology that how to propose short flow process, near-net-shape and be easy to control.
On the other hand, in the medium-term and long-term development plan of national Eleventh Five-Year Plan, clearly propose following processing industry and must walk low energy consumption, oligosaprobic road, and proposed corresponding performance assessment criteria.For reversing the materials processing that in China's economic construction, occupies critical role and high energy consumption, heavily contaminated and the low cost performance of manufacturing as early as possible, improve the quality of products, alleviate environmental pollution, strengthen its international competitiveness, press for from metallurgical material scientific development forward position, break through traditional metallurgy and processing technology theory and notion, utilize new and high technology that new technology exploration is carried out in materials processing and control technology, realize short flow process, low energy consumption and the high-quality of production process.The appearance of phase early 1970s semi-solid processing has brought hope for addressing the above problem undoubtedly.
So-called semi-solid processing is that the solid-liquid mixed slurry with certain liquid phase component is carried out die casting, extruding or die-forging forming, be a kind of manufacturing process (M.C.Flemings.Behavior of Alloys in Semi-solid State.Metallurgical Transactions between conventional cast (pure liquid state) and forging and pressing (pure solid-state), 1990, Vol.22B:269-293).Compare with common processing method, semi-solid-state metal processing has following advantage: 1. have wide range of applications, all metal and alloys with solid-liquid two-phase region all can be realized semi-solid processing, as die casting, extruding and the excellent suitability for press forming of aluminium alloy, magnesium alloy and steel; 2. semi-solid alloy partly discharges crystallization latent heat, thereby has alleviated the thermal shock to processing mold, and its life-span is increased substantially; 3. semi solid slurry has rheological characteristic and thixotropy, and resistance of deformation is very little, thereby the very complicated parts of section that can be shaped, and realizes near-net-shape, and has shortened the process-cycle, has improved stock utilization, helps energy-saving material-saving; 4. the semi solid slurry filling is steady, no turbulent flow and splash, and processing temperature is relatively low, and solidification shrinkage is little, thereby the drip molding surfacing is smooth, dense internal organization, crystal grain is tiny, and mechanical property is good.As seen semi-solid processing is compared with traditional process technology and is had great advantage (Simon Kleiner, Erhard Ogris, OliverBeffort and Peter J.Uggowitzer.Semi-Solid Metal Processing of Aluminum Alloy A356 andMagnesium Alloy AZ91:Comparison Based on Metallurgical Considerations.AdvancedEngi.Mater.2003,5 (9): 653-658).
Since the seventies in 20th century, this technology has obtained the U.S., Italy, the scientific workers' of developed country such as Germany and Japan generally attention, and successively to aluminium, magnesium, plumbous, alloys such as copper have been carried out extensive studies at aspects such as semisolid technological experiment and theories, obtained impressive progress, part company has entered large-scale production (M.Fehlbier.Herstellung, Charakterisierung und Verarbeitung Teilfluessiger Metallischer Werkstoffe amBeispiel Verschiedener Aluminum-und Magnesiumlegierungen.Aachen, Techn.Hochsch., Diss, 2002.ISBN3-8322-1064-4).Production capacity as two semi-solid aluminium alloy shaping auto parts production plants in 1997 of Alumax company of the U.S. reaches annual 5000 ten thousand respectively.The semi-solid aluminium alloy auto parts quality that gondola Stampal SPA and Fiat Auto company produce reaches 7kg, and complex-shaped; Gondola MM (Magneti Marelli) produced the fuel injection rail part that semi-solid aluminium alloy is shaped for motor corporation, reached 7500 of daily outputs in 2000.In Germany, metal forming institute of world-renowned RWTH (IBF derRWTH-Aachen) under Reiner Kopp professor and EFU president of a company Gerhalt professor Hirt lead, just carrying out one large-scale, the semisolid research project SFB289 (Sonderforschungbereich) that level is very high, this project continuous 12 years from 1996 obtains subsidy from the German scientific research DFG of federation (Deutsche Forschungsgemeinschaft), semisolid has been carried out comprehensively, deeply and the basic research and the commercial development (M.Kiuchi of system, R.Kopp.Mushy/Semi-solid metal forming technology-Present and future.Annals of the CIRP.2002,51 (2): 1-18).The Speed Star Wheel company of Japan produces aluminium alloy wheel hub (heavy 5kg) with semi-solid processing.In addition, produce mobile communication phone shell and notebook computer casing etc. with semi-solid magnesium alloy thixotropic forming technology in some companies of Japan.In worldwide, successively hold 10 international academic conferences (S2P) of semisolid, obtained important academy's successes.
China is since the later stage eighties, in state natural sciences fund, under the support of plans such as 863 and 973, successively there are many colleges and universities and R﹠D institution to carry out the research of this respect, as (the Zhang Jingxin of Beijing Non-Ferrous Metal Research General Academy, Zhang Kui, Xu Jun, Shi Li opens second semisolid nd Annual Meeting collection of .Semi-solid Processing of AZ91D Alloy. China. Beijing, 2002:204-208), (the Zuo Hongzhi of University Of Chongqing, Liu Changming, Zou Maohua, Gu Zhongming, model increases, Li Dequan, Wu Jun, the semisolid casting forming of the auspicious .ZL112Y pack alloy of Qiu's filial piety semisolid remelting technology and motorcycle parts. second semisolid nd Annual Meeting collection of China. Beijing, 2002:102-109) etc.Obtaining encouraging progress aspect the fundamental research of semi-solid processing forming technique, and idiomorphism design and developed dissimilar testing equipments, even test production with business tie-up.JH70 type motor generator magnesium alloy semi solid state support as University Of Chongqing and Chongqing nine sides of China Jialing group casting Co., Ltd cooperation research and development; The Beijing Non-Ferrous Metal Research General Academy cooperates with the Dong Feng Auto Corporation, the aluminium alloy automobile air-conditioner part that adopts semisolid die casting to produce.
In the semi-solid-state shaping process, semi solid slurry is considered to not have the laminar flow (non newtonian flow behavior) of turbulent feature at the die cavity stowing operation, in theory, this no turbulent slurry fills can be avoided defectives such as the normal pore that occurs, steam bubble in routine casting, formation has the drip molding of strong mechanical performance, and laminar flow has the flow front of sealing, is mingled with to reduce oxide etc.Yet the shrinkage cavity that folding line that often discovery is ftractureed in actual production process, material overlaps to form and local material shrinkage form, this may be that semi-solid processing is difficult to realize large-scale industrial production ground partly cause.With respect to the semisolid casting forming, in Semi-Solid Thixoforming forging or extrusion process, to the fraction solid requirement raising significantly of heating blank, its liquid phase fraction is considered to use as lubricating usually.Consequent result is that the tendency that produces turbulent flow in the slurry fills process reduces, and the possibility that produces the sealing forward position also reduces simultaneously yet material flows, and forward position cracking possibility strengthens.Thereby the semi-solid flow forward position goed deep into and systematic research has great importance, the raising to part quality in the actual production simultaneously has important directive function.
In fact, in the semi-solid-state shaping process, slurry is owing to reasons such as heat radiation, thermal convection current and heat conduction are progressively solidified in deformation process, thereby the semi-solid-state shaping process is finished under non-isothermal condition in itself.Because heat energy parameters such as hot conduction parameter and heat emissivity coefficient can't change in actual production, thereby can only carry out from two aspects the improvement of flow front: the mould movement velocity the control forming process or the method by mould optimization changes mould structure and size realizes.On the other hand, the semi-solid processing temperature range is very narrow usually, and its forming process must be finished in a short period of time.This requires forming press that high positional precision is not only arranged, and simultaneously higher slide block movement speed must be arranged.The liquid phase fraction of heating blank is controlled at below 30% usually in the thixotroping forging and molding, thereby can be avoided by the slurry turbulent flow filling phenomenon that the mold high speed motion is produced, but flow front cracking problem may take place.
Summary of the invention
The object of the present invention is to provide a kind of die design method and forming technology that improves quality of semi-solid forge pieces, with the cracking that solves flow front in the Semi-Solid Thixoforming forging and molding process with problem such as do not seal.
The present invention uses the not closure state that the method for mould size optimization is improved flow front in the Semi-Solid Thixoforming forging and molding, and research object is the flange part (Fig. 1) that once-forming is forged in thixotroping.
With the circular flange is research object, and to the flange of trapezoid cross section, certain angle of inclination (10-20 °), blank must constantly could farthest improve forging quality at the flow of each radius of flange during shaping, prevents the generation of the situation of ftractureing.The radially filling velocity of supposing blank is Vr, the maximum outside diameter of flange is R, maximum outside diameter R place flange thickness is h (5mm＜h＜7mm), radius is that (thickness that 0＜r＜R) locates flange is H (r) to r, it is identical that this thickness H (r) must satisfy the flow front area, i.e. H (r) * 2 π r=C (C is a constant).Because the radially filling velocity of blank can be optimized by regulating press forming speed and blank semi-solid temperature, make it to become and the irrelevant constant of radius size, the flow front area multiply by radially filling velocity and also is constant like this, be H (r) * 2 π r * Vr=constant, just radially volume flow equates all the time.Thereby the cracking problem fundamentally having solved Semi-Solid Thixoforming forging flow front has improved forging quality.
Concrete processing step is as follows:
1, blank is prepared.Buy or prepare the bar with microstructure of semisolid feature of certain diameter, the blank of required size is processed in sawing.
2, blank is carried out eddy-current heating.With induction heater the blank rapid and uniform heating is arrived the needed semi-solid temperature of thixotroping forging and molding (to A356 aluminium alloy: 577-581 ℃).
3, the mould of Semi-Solid Thixoforming forging and molding flange part design.Fig. 2 and Fig. 3 be in the Semi-Solid Thixoforming forging and molding process slurry along the schematic diagram of the identical area of radial direction flow front.The forming cavity design of flange is in the bottom level direction of thixotroping forging mold patrix.Because described part is axially symmetrical, radially inwardly determining 5-8 equidistant points earlier from maximum outside diameter R, as: determine P1 ' to P6 ' (P1 ' P2 '=P2 ' P3 '=...=P5 ' P6 '=L, L=6mm), determine P1 to P6 according to its principle that circumferential area equates on short transverse again, just S1=S2=...=S6 (S is the flow front area).Obtain being shaped as a hyperbola by P1 is linked to be line to P6, and then form hyperboloid, i.e. the curvature portion of mould flange forming cavity, this be the important evidence that patrix flange forming cavity designs.
4, Semi-Solid Thixoforming forging and molding flange part.Semi-solid blank behind the eddy-current heating is put in the die of preheating (preheat temperature 250-300 ℃) thixotroping forging mold excessively with anchor clamps rapidly.(to the A356 aluminium alloy: 80-120mm/s), making slurry radial velocity in stowing operation radially is steady state value, and slurry can be realized the filling mode (H (r) * 2 π r * Vr=constant) of equal-volume flow in filling radially like this to adjust the speed of forcing press.Use the graphite releasing agent, and the pressurize certain hour.But use above parameter thixotroping forging and molding to obtain having the high-quality flange part of sealing flow front.
Advantage of the present invention: a kind of die design method and forming technology that improves quality of semi-solid forge pieces is provided, make semi solid slurry in shaping, realize the filling of equal-volume flow, problem such as solved the cracking of flow front in the Semi-Solid Thixoforming forging and molding process and do not seal.Parts clear-cut after the shaping, dimensionally stable are accurate, and mechanical property is better than the conventional material goods greatly, have obtained having the high-quality forging of sealing flow front.In fact, the mould designing technique of these volume flows also can be used for other complex parts that quality is had higher requirements or the part that local quality is had higher requirements.Therefore, this method has certain versatility.
Description of drawings
Fig. 1 forges the schematic diagram of once-forming flange part for Semi-Solid Thixoforming.
Fig. 2 is the model schematic diagram (axial symmetry 1/4 model) that slurry flows along radial direction in the Semi-Solid Thixoforming forging and molding process, P1 ', P2 ' ..., P6 ' be respectively P1, P2 ..., the projection of P6 on flange lower surface (x axle).
Fig. 3 is that slurry is along the schematic diagram of the geometric description of the identical area of radial direction flow front in the Semi-Solid Thixoforming forging and molding process, and the x axle is a flange lower surface radial direction.
Specific embodiment
Use Semi-Solid Thixoforming forging and molding method to prepare flange part.
Embodiment 1:
Buying diameter from Duralcan company (Duralcan company) is the A356 aluminium alloy bar with microstructure of semisolid feature of φ 50mm.The cylindric blank of φ 50mm * 52mm is processed in sawing, with induction heater with the blank rapid and uniform heating to semi-solid temperature: 581 ℃.
The mould of design Semi-Solid Thixoforming forging and molding flange part.The forming cavity design of flange is in the bottom level direction of thixotroping forging mold patrix, size according to research axial symmetry target part, the lower surface of flange forming cavity radially (x axle) inwardly determine 7 equidistant points from maximum outside diameter R, be P1 ' to P7 ' (P1 ' P2 '=P2 ' P3 '=...=P6 ' P7 '=L, L=8mm wherein), determine P1 to P7 according to its principle that circumferential area equates on short transverse again, just S1=S2=...=S7 (S is the flow front area).Obtain being shaped as a hyperbola by P1 is linked to be line to P7, and then form hyperboloid, be the curvature portion of mould flange forming cavity.
Semi-solid aluminium alloy blank behind the eddy-current heating is put in the die of thixotroping forging mold (mold preheating temperature is made as 260 ℃) with anchor clamps rapidly.The speed of forcing press is adjusted into 80mm/s, uses the graphite releasing agent, and forming pressure is made as 600KN, and the dwell time was made as 8 seconds.But use above parameter forging and molding to obtain having the high-quality flange part of sealing flow front.
Embodiment 2:
With diameter is the cylindric blank that φ 50mm * 55mm is processed in the A356 aluminium alloy bar sawing with microstructure of semisolid feature of φ 50mm, with induction heater with the blank rapid and uniform heating to semi-solid temperature: 579 ℃.
The mould of design Semi-Solid Thixoforming forging and molding flange part.The forming cavity design of flange is in the bottom level direction of thixotroping forging mold patrix, size according to research axial symmetry target part, the lower surface of flange forming cavity radially (x axle) inwardly determine 6 equidistant points from maximum outside diameter R, be P1 ' to P6 ' (P1 ' P2 '=P2 ' P3 '=...=P5 ' P6 '=L, L=7mm wherein), determine P1 to P6 according to its principle that circumferential area equates on short transverse again, just S1=S2=...=S6 (S is the flow front area).Obtain being shaped as a hyperbola by P1 is linked to be line to P6, and then form hyperboloid, be the curvature portion of mould flange forming cavity.
Semi-solid aluminium alloy blank after using simple and easy conveying device with eddy-current heating is put into the die (mold preheating temperature is made as 260 ℃) of thixotroping forging mold rapidly.The speed of forcing press is adjusted into 100mm/s, uses the graphite releasing agent, and forming pressure is made as 600KN, and the dwell time was made as 8 seconds.But use above parameter forging and molding to obtain having the high-quality flange part of sealing flow front.
Embodiment 3:
With diameter is the cylindric blank that φ 50mm * 61mm is processed in the A356 aluminium alloy bar sawing with microstructure of semisolid feature of φ 50mm, with induction heater with the blank rapid and uniform heating to semi-solid temperature: 577 ℃.
The mould of design Semi-Solid Thixoforming forging and molding flange part.The forming cavity design of flange is in the bottom level direction of thixotroping forging mold patrix, size according to research axial symmetry target part, the lower surface of flange forming cavity radially (x axle) inwardly determine 5 equidistant points from maximum outside diameter R, be P1 ' to P5 ' (P1 ' P2 '=P2 ' P3 '=...=P4 ' P5 '=L, L=6mm wherein), determine P1 to P5 according to its principle that circumferential area equates on short transverse again, just S1=S2=...=S5 (S is the flow front area).Obtain being shaped as a hyperbola by P1 is linked to be line to P5, and then form hyperboloid, be the curvature portion of mould flange forming cavity.
Semi-solid aluminium alloy blank after using simple and easy conveying device with eddy-current heating is put into the die (mold preheating temperature is made as 260 ℃) of thixotroping forging mold rapidly.The speed of forcing press is adjusted into 120mm/s, uses the graphite releasing agent, and forming pressure is made as 600KN, and the dwell time was made as 8 seconds.But use above parameter forging and molding to obtain having the high-quality flange part of sealing flow front.
Claims (2)
1. a die design method and forming technology that improves quality of semi-solid forge pieces, it is characterized in that with the circular flange being research object, flange to trapezoid cross section, 10-20 ° of angle of inclination, blank keeps constant at the flow of each radius of flange during shaping, the radially filling velocity of supposing blank is Vr, the maximum outside diameter of flange is R, maximum outside diameter R place flange thickness is h, 5mm＜h＜7mm wherein, radius is that the thickness of r place flange is H (r), 0＜r＜R, and it is identical that this thickness H (r) must satisfy the flow front area, be H (r) * 2 π r=C, C is a constant; The radially filling velocity of blank is undertaken by regulating press forming speed and blank semi-solid temperature, making radially, filling velocity becomes and the irrelevant constant of radius size, the flow front area multiply by radially filling velocity and also is constant like this, be H (r) * 2 π r * Vr=constant, just radially volume flow equates all the time.
2. a kind of according to claim 1 die design method and forming technology that improves quality of semi-solid forge pieces is characterized in that concrete processing step is as follows:
1), blank is prepared; The bar that purchase or preparation have the microstructure of semisolid feature, the blank of required size is processed in sawing;
2), blank is carried out eddy-current heating, with induction heater with the blank rapid and uniform heating to the needed semi-solid temperature of thixotroping forging and molding; To A356 aluminium alloy: 577-581 ℃;
3), the mould of Semi-Solid Thixoforming forging and molding flange part design; The forming cavity design of flange is in the bottom level direction of thixotroping forging mold patrix; Because described part is axially symmetrical, radially inwardly determining 5-8 equidistant points earlier from maximum outside diameter R; With respect to 6 equidistant points: determine P1 ' to P6 ', P1 ' P2 '=P2 ' P3 ' P3 '=...=P5 ' P6 '=L, L=6mm; The principle that equates according to its circumferential area on short transverse is determined P1 to P6 again, S1=S2=...=S6 just, and S is the flow front area; Obtain being shaped as a hyperbola by P1 is linked to be line to P6, and then form hyperboloid, i.e. the curvature portion of mould flange forming cavity, this be the important evidence that patrix flange forming cavity designs;
4), Semi-Solid Thixoforming forging and molding flange part; Semi-solid blank behind the eddy-current heating is put in the die of thixotroping forging mold of preheating with anchor clamps rapidly, and preheat temperature is 250-300 ℃; Adjust the speed of forcing press, to A356 aluminium alloy: 80-120mm/s, making slurry radial velocity in stowing operation radially is steady state value, and slurry can be realized the filling mode of equal-volume flow, H (r) * 2 π r * Vr=constant in filling radially like this.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104525799A (en) * | 2014-12-26 | 2015-04-22 | 西安交通大学 | Large ring semisolid manufacturing process using radial-axial rolling strain induction method |
| CN104726809A (en) * | 2015-02-06 | 2015-06-24 | 西安交通大学 | Radial forging type strain-induced semi-solid integral die forging process of blade |
| CN115283471A (en) * | 2022-10-08 | 2022-11-04 | 中北大学 | Forward extrusion uniform forming method for complex section |
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2009
- 2009-09-02 CN CN200910090638A patent/CN101648253A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104525799A (en) * | 2014-12-26 | 2015-04-22 | 西安交通大学 | Large ring semisolid manufacturing process using radial-axial rolling strain induction method |
| CN104525799B (en) * | 2014-12-26 | 2016-05-25 | 西安交通大学 | The semisolid manufacturing process of the radial-axial rolling strain-induced method of large ring |
| CN104726809A (en) * | 2015-02-06 | 2015-06-24 | 西安交通大学 | Radial forging type strain-induced semi-solid integral die forging process of blade |
| CN115283471A (en) * | 2022-10-08 | 2022-11-04 | 中北大学 | Forward extrusion uniform forming method for complex section |
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Open date: 20100217 |