CN104785706A - Die forging forming machining method for high-neck flange - Google Patents
Die forging forming machining method for high-neck flange Download PDFInfo
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- CN104785706A CN104785706A CN201410613167.5A CN201410613167A CN104785706A CN 104785706 A CN104785706 A CN 104785706A CN 201410613167 A CN201410613167 A CN 201410613167A CN 104785706 A CN104785706 A CN 104785706A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/14—Making machine elements fittings
- B21K1/16—Making machine elements fittings parts of pipe or hose couplings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
Abstract
The invention provides a die forging forming machining method for a high-neck flange. The method includes the first step of blanking; the second step of heating; the third step of pre-forging, wherein materials are discharged to a 8T full hydraulic free forging electro-hydraulic hammer from a forging furnace through a manipulator to conduct heading, the initial forging temperature is 1250 DEG C +/- 20 DEG C, forging time is about 10-15 seconds, the number of hammering times is about 5-6, and the size meeting technological requirements is achieved; the fourth step of die forging, wherein a workpiece is moved to a die forging working area and subjected to die forging through a die forging electro-hydraulic hammer, the final forging temperature is 1050 DEG C +/- 20 DEG C, forging time is about 20-30 seconds, the number of hammering times is about 6-8, and a die cavity demands to be completely filled with a blank; the fifth step of edge trimming and punching; the sixth step of checking; the seventh step of heat treatment; the eighth step of checking; the ninth step of marking and warehousing. According to the method, the labor intensity of forgers is substantially relieved, the usage quantity of materials is remarkably reduced, environmental pollution is controlled effectively, and production cost is remarkably lowered.
Description
technical field:
The present invention relates to a kind of hubbed flange die-forging forming processing method, belong to precision forging and technical field of automatic control.
background technology:
Flange is the common components on pipeline, belong to pressure pipeline element, be widely used on the pipeline of the industry such as oil, chemical industry, shipbuilding, nuclear power, power plant construction, extra-high voltage conveying electricity, food, pharmacy, Aero-Space, non-ferrous metal metallurgy, urban water supply, papermaking.A large amount of use stainless steel American Standard hubbed flange (ASME B16.5 WN) product under the environment such as high temperature, low temperature, corrosion.At present, domestic flange manufacturing enterprise Forging Technology generally adopts open die forging, swage forging conventional forging process, material consumption amount is large, labour intensity is large, energy consumption is high, production efficiency is low, quality stability is poor, environmental pollution is serious, cause production cost to remain high, lack the market competitiveness.
Tradition stainless steel American Standard hubbed flange (ASME B16.5 WN) shaping process: (for ASME B16.5 150Lb WN16 " sch40s F316L product):
A. the stainless steel bar through being up to the standards, by cutting stock weight requirement in technology for blanking at band sawing machine loading and unloading (this product cutting stock weight 130KG).
B. lower good material is put in coal furnace or coal-fired reverberatory furnace or combustion gas straight-flow furnace and be heated to 1200 DEG C ~ 1250 DEG C (coal furnace is seriously polluted, and energy ezpenditure is large) by heating process requirement.
C. on pneumatic hammer or suspender belt hammer, carry out that base, pier are thick, punching, then melt down and be heated to initial forging temperature, reaming on the saddle support of another pneumatic hammer; Third time melts down heating, then to shaping in fetal membrane (repeatedly heat energy consumption large, efficiency hand-manipulated is low, and labour intensity is large).
D. measure each spot size, meet processes requirement, Zhuan Xia road heat treatment step; Undesirable, then continue to melt down heating, shaping, to meet the requirement of each spot size.
E. workpiece is heat-treated, carry out solutionizing process by technological requirement, adopt water-cooled.
F. workpiece tested, mark, remember information such as having product batch number, material charge number, product specification, material.
G. certified products enter roughcast warehouse, and defective work is disposed by " control procedure of nonconforming products ".
summary of the invention:
The object of the invention is to provide a kind of hubbed flange die-forging forming processing method for above-mentioned Problems existing, pass through the absorption of technology, production efficiency is made to become the raising of decades of times, energy consumption reduces by more than 50 percent, owing to using the operation of manipulator, industrial robot, forger labour intensity declines to a great extent, and materials are than significantly reducing, environmental pollution is controlled effectively, and production cost obviously declines.
Above-mentioned object is achieved through the following technical solutions:
Hubbed flange die-forging forming processing method, the method comprises the following steps:
A. blanking: the stainless steel rod iron through being up to the standards, by the cutting stock weight specified in technology for blanking in band sawing machine loading and unloading, requires that cutting stock weight deviation controls in ± 1% scope;
B. heat: with manipulator, lower good material is added in forge furnace, be heated to 1250 DEG C ± 20 DEG C by heating process requirement, about 85 ± 10 minutes heat times;
C. blocking: thick to the all-hydraulic free forging electrohydraulic hammer pier of 8T with manipulator discharging from forge furnace, initial forging temperature 1250 DEG C ± 20 DEG C, forging time about 10-15 seconds, cycle about 5-6 times, reaches the size of technological requirement;
D. die forging: workpiece is forged workspace from shifting formwork, carries out die forging with die forging electrohydraulic hammer, final forging temperature 1050 DEG C ± 20 DEG C, forging time 20-30 seconds, and cycle 6-8 times, requires that blank is full of die cavity completely;
E. trimming, punching: select closed type single point press compound trimming die;
F. check: after air cooling to room temperature, 100% checks forging ' s block dimension specification and surface quality;
G. heat treatment: by solid solution treatment process requirement, heats, insulation in 2 10T heat accumulating type cell-type gas furnaces, and manipulator is come out of the stove quick water-cooled to the tank of below;
H. check: every melting batch random selecting Work inspection device hardness HB:137-187;
I. mark, put in storage, same to traditional handicraft.
Described hubbed flange die-forging forming processing method, the system of selection of the die forging electrohydraulic hammer tonnage described in step D is: need selected forging hammer tonnage G(kg according to finish-forging work step): G=(3.5-6.3) kF
always
In formula: F
alwaysrepresent forging total deformation area, unit is cm
2, comprise forging area, punching core material and overlap area,
K represents steel grade coefficient, when the carbon structural steels adopting phosphorus content lower than 0.25%, K gets 0.9, when adopt phosphorus content higher than 0.25% carbon structural steels and the low-alloy steel of C≤0.25% time, K gets 1, and when adopting the low-alloy structural steel of phosphorus content >=0.25%, K gets 1.1, when adopting high alloy-structural steel, stainless steel, K gets 1.25.
Described hubbed flange die-forging forming processing method, the closed type single point press tonnage P(KN described in step e), select according to forging hammer tonnage G: P=MG
In formula: M is combo coefficient, M=800-1000KN/t.
Described hubbed flange die-forging forming processing method, the heat treatment described in step G adopts gas heat-accumulated type heat-treatment furnace.
Described hubbed flange die-forging forming processing method, is provided with indirect vibration isolator in the basis of the Single arm of described blocking and described die forging.
Described hubbed flange die-forging forming processing method, in described die forging, forging die is made up of upper and lower two modules, be fastened in the dovetail groove of tup and die shoe by means of dovetail, drift and key block, described dovetail: module is fixed on tup or anvil block, makes dovetail bottom surface and tup or anvil block bottom surface fit tightly; Described drift: module is located at left and right directions; Described key block: module is located at fore-and-aft direction.
Beneficial effect:
1. carry out the automatic assembly line mode of production in production process of the present invention, labour intensity significantly reduces, and production efficiency significantly improves, constant product quality, and accepted product percentage reaches more than 99.9%.
2. material consumption of the present invention is little, and materials are than obviously reducing, and the uniformity of product is good, carries out digital control processing and creates conditions, improve the output of rear road processing to the machined of rear road.
3. the present invention adopts regenerative gas heating furnace or intermediate frequency induction heating device, and material oxidation is few, because one-time heating energy consumption significantly reduces.
4. forging hammer of the present invention adopts indirect vibration isolation, and vibration isolating effect is good, does not substantially cause vibration pollution to surrounding environment.
5. the econmics comparison of the present invention and traditional handicraft.(for ASME B16.5 WN/RF 150Lb 16 " sch40s F316L product)
| Forging method | Finished weight (kg) | With doses (kg) | Materials ratio | Class produces (part) | Manually (unit/part) | Combustion gas (m3/ part) |
| Tradition open die forging | 64.41 | 130 | 2.02 | 35 | 97.5 | 32.5 |
| Precision die forging | 64.41 | 107.8 | 1.67 | 480 | 5.2 | 13.3 |
As can be seen from the above table, precision die forging materials are than decline 20.6% compared with traditional open die forging, and class's product is 13.7 times of free forging process, is manually 5.3% of traditional handicraft, and combustion gas uses and accounts for 40.9% of traditional handicraft.
detailed description of the invention:
Embodiment 1:
Hubbed flange die-forging forming processing method, the method comprises the following steps:
A. blanking: the stainless steel rod iron (being preferably round steel) through being up to the standards, by the cutting stock weight specified in technology for blanking, in band sawing machine loading and unloading, (small dimension product can be round with stainless steel light, directly use bar shears blanking), require that cutting stock weight deviation controls in ± 1% scope.(this product cutting stock weight is 147.5kg, core material weight 39.7kg, actual feed consumption 107.8kg after forging, and core material can do 6 " 300Lb WN product).
B. heat: forge furnace adopts heat accumulating type cell-type gas-fired heater (2T, 3T die forging production line can select Frequency Induction Heating complete set of equipments).Be provided with PLC control system, control firing rate, initial forging temperature, reaction temperature uniformity, furnace pressure etc.With manipulator, lower good material is added in forge furnace, be heated to 1250 DEG C ± 20 DEG C by heating process requirement, about 85 minutes heat times.
C. blocking: thick to the all-hydraulic free forging electrohydraulic hammer pier of 8T with manipulator discharging from forge furnace, initial forging temperature 1250 DEG C ± 20 DEG C, forging time about 10-15 seconds, cycle about 5-6 times, reaches the size of technological requirement.
D. die forging: with 16T die forging electrohydraulic hammer, 400kg rail industrial robot, moves to workspace 16T hammer workpiece from 8T hammer, carries out die forging, final forging temperature 1050 DEG C ± 20 DEG C, forging time 20-30 seconds, cycle 6-8 times, requires that blank is full of die cavity completely.
E. trimming, punching: select JS31-1600 type closed type single point press, compound trimming die.From 16T die hammer, the workpiece after die forging is moved on JS31-1600 type closed type single point press with 400kg rail industrial robot, put positive position, carry out trimming, punching.Trimming temperature >1000 DEG C, once completes trimming, punching.After completion, blank, core material, overlap separate collection are stacked.
F. check: after air cooling to room temperature, 100% checks forging ' s block dimension specification and surface quality
G. heat treatment: by solid solution treatment process requirement, heats, insulation in 2 10T heat accumulating type cell-type gas furnaces, and manipulator is come out of the stove quick water-cooled to the tank of below.
H. check: every melting batch random selecting Work inspection device hardness HB:137-187.
I. mark, put in storage, same to traditional handicraft.
Technology point:
Equipment choice:
Capital equipment die hammer and closed type single point press are selected:
Forging hammer tonnage: need selected forging hammer tonnage G(kg according to finish-forging work step): G=(3.5-6.3) kF
always,
In formula: F
always-forging total deformation area, cm
2, comprise forging area, punching core material and overlap area.K-steel grade coefficient, stainless steel material k selects 1.25.
Closed type single point press: closed type single point press, forge furnace, die hammer form base unit-unit that die forging is produced.Combo press tonnage P(KN), can select according to forging hammer tonnage G, P=MG,
In formula: M-combo coefficient, different with forging hammer tonnage size, desirable M=800-1000KN/t, with the clipping press that die hammer is supporting
| Die hammer falls part mass/t | Forcing press nominal pressure/KN |
| 0.5 | 1000 |
| 0.75 | 1250 |
| 1 | 1600 |
| 2 | 2000 |
| 3 | 3150 |
| 5 | 4000—6300 |
| 10 | 8000—10000 |
| 16 | 12500—16000 |
Forge furnace is selected:
Mini-plant such as 2T, 3T die hammer precision die forging selects the Frequency Induction Heating complexes of non-oxidation or few oxidation.
Main equipment such as 6T, 10T, 16T die forging production line adopts regenerative gas chamber-type forge furnace.
Transport operation is carried out with dress reclaimer or industrial robot between heating, blocking, die forging, edge-cutting and hole-punching-separation, each operation.
Mini-plant unit, as 2T, 3T die forging line, because the workpiece of processing is fewer, adopts sprocket wheel carrier bar pipeline, carries out workpiece conveying.
Main equipment unit, as 6T, 10T, 16T die forging production line employing forging manipulator, industrial robot carry out workpiece and take, operate.
Equipment for Heating Processing:
Select gas heat-accumulated type heat-treatment furnace.For the heat-treatment furnace of stainless steel solid solution, adopt cell-type regenerative gas stove.Design furnace temperature 1400 DEG C, dress workpiece amount 10T × 2,175m3 pond, is provided with cooling water system, and 10T fills reclaimer and forge furnace share a set of control system, strengthens coordinated signals.9 thermometrics, guarantee certainty of measurement ± 1 DEG C, temperature uniformity ± 10%, water temperature less than 50 DEG C.
For straight carbon steel, steel alloy heat-treatment furnace.Dress workpiece amount 20T is set, heat accumulating type Type Car-bottom Heat Treating Furnace.Design the highest production temperature 1000 DEG C, 9 measurements, guarantee certainty of measurement ± 1 DEG C, temperature uniformity ± 10%.
Forging hammer vibration isolation:
Forging hammer can produce larger vibration in the course of the work, if improper to foundation of forging hammers design, vibration not only will have a strong impact on the work of surrounding devices, reduce the stability of mill construction, even can be detrimental to health, we select by the indirect vibration isolator scheme of Guangzhou An Gu vibration isolation Environmental Protection Technology Co., Ltd in the free forging electrohydraulic hammer of 8T and the basic engineering of 16T die forging electrohydraulic hammer.
The technical scheme (indirect vibration isolation) of 8 tons of free forging electrohydraulic hammer vibration isolators:
1, the technical parameter of forging hammer:
Blow energy: 280KJ,
Fall part mass: 8.5T,
The maximum strike frequency: 55 beats/min,
Overall mass: 205T,
Configuration concrete quality block: 10000 × 6000 × 5400(weight is about 775T)
2, the technical parameter (indirect vibration isolation) of vibration isolator:
The technical scheme (indirect vibration isolation) of 16 tons of electric liquid die hammer vibration isolators:
1, the technical parameter of forging hammer:
Blow energy: 400KJ
Fall part mass: 18.5T+18.5T
The maximum strike frequency: 40 beats/min
Overall mass: 440T
Configuration concrete quality block: 10000 × 8000 × 5600(weight is about 1060T)
2, the technical parameter (indirect vibration isolation) of vibration isolator
Design of forging die
Die hammer design of forging die:
1. adopt open die forging, impressing forging, use combination die.Mould bases dimensions is fixed, products of different specifications die change core.Forging die is made up of upper and lower two modules, is fastened in the dovetail groove of tup and die shoe by means of dovetail, drift and key block.
Dovetail: module is fixed on tup (or anvil block), makes dovetail bottom surface and tup (or anvil block) bottom surface fit tightly.
Drift: module is located at left and right directions.
Key block: module is located at fore-and-aft direction.
This design feature: owing to adopting open die forging, impressing forging, have overlap to exist.The filling performance of impression is better.Energy device determined by die hammer, and what its energy carried out autokinesis falls part, comprises tup, hammer stem and upper module etc.Distortion can be completed by repeatedly hammering, be particularly suitable for the production of stainless steel product.During die forging, blank axis direction is identical with beating position, and metal plastic deformation occurs along height, width and length direction simultaneously.
Draft angle is generally between 5 °-15 °.
Die forging radius of corner: forging part round radius (r) of steel generally gets 1.5-12mm, larger than round radius 2-3 times of fillet radius (R).Depth of die cavity is darker, and radius of corner value is larger.Detect for the ease of molding and forging, radius of corner size forms series, and its standard is 1,1.5,2,2.5,3,4,5,6,8,10,12,15,20,25,30 mm such as grade.
Use the technical requirement of forging die:
First check impression workmanship and installation dimension whether qualified.
Forging die should be solid and reliable, and upper and lower mould die joint balances mutually, and dovetail height should be greater than the degree of depth of dovetail groove, clearance delta=0.5-1mm.
Gap between adjustment tup and guide rail, under the prerequisite ensureing normal work, gets minimum of a value as far as possible.
Forging die should be preheating to 150-350 DEG C before use, should be incubated when making to pause in purposes.
Iron scale has a strong impact on forging quality and hammer die lif, conscientiously must remove the iron scale of heating blank surface before forging.
Surface temperature during forging die work more than 400 DEG C, for preventing forging die intensification too high, must not should spray cooling lubricant to impression.
Edge-cutting and hole-punching composite die designs:
Drop stamping is based upon on the basis of metal plastic deformation, at high temperature utilizes the mould be arranged on forcing press to apply pressure to workpiece, make it produce separation.Thus obtain definite shape, size and performance a kind of pressure processing method.
This technique mainly uses edge-cutting and hole-punching compound die.
Below be only most preferred embodiment of the present invention, method of the present invention includes but not limited to above-described embodiment, and unaccomplished matter of the present invention belongs to the common practise of those skilled in the art.
Claims (6)
1. a hubbed flange die-forging forming processing method, is characterized in that: the method comprises the following steps:
A. blanking: the stainless steel rod iron through being up to the standards, by the cutting stock weight specified in technology for blanking in band sawing machine loading and unloading, requires that cutting stock weight deviation controls in ± 1% scope;
B. heat: with manipulator, lower good material is added in forge furnace, be heated to 1250 DEG C ± 20 DEG C by heating process requirement, about 85 ± 10 minutes heat times;
C. blocking: thick to the all-hydraulic free forging electrohydraulic hammer pier of 8T with manipulator discharging from forge furnace, initial forging temperature 1250 DEG C ± 20 DEG C, forging time about 10-15 seconds, cycle about 5-6 times, reaches the size of technological requirement;
D. die forging: workpiece is forged workspace from shifting formwork, carries out die forging with die forging electrohydraulic hammer, final forging temperature 1050 DEG C ± 20 DEG C, forging time 20-30 seconds, and cycle 6-8 times, requires that blank is full of die cavity completely;
E. trimming, punching: select closed type single point press compound trimming die;
F. check: after air cooling to room temperature, 100% checks forging ' s block dimension specification and surface quality;
G. heat treatment: by solid solution treatment process requirement, heats, insulation in 2 10T heat accumulating type cell-type gas furnaces, and manipulator is come out of the stove quick water-cooled to the tank of below;
H. check: every melting batch random selecting Work inspection device hardness HB:137-187;
I. mark, put in storage.
2. hubbed flange die-forging forming processing method according to claim 1, is characterized in that: the system of selection of the die forging electrohydraulic hammer tonnage described in step D is: need selected forging hammer tonnage G(kg according to finish-forging work step): G=(3.5-6.3) kF
always,
In formula: F
alwaysrepresent forging total deformation area, unit is cm
2, comprise forging area, punching core material and overlap area,
K represents steel grade coefficient, when the carbon structural steels adopting phosphorus content lower than 0.25%, K gets 0.9, when adopt phosphorus content higher than 0.25% carbon structural steels and the low-alloy steel of C≤0.25% time, K gets 1, and when adopting the low-alloy structural steel of phosphorus content >=0.25%, K gets 1.1, when adopting high alloy-structural steel, stainless steel, K gets 1.25.
3. hubbed flange die-forging forming processing method according to claim 1 and 2, is characterized in that: the closed type single point press tonnage P(KN described in step e), select according to forging hammer tonnage G: P=MG
In formula: M is combo coefficient, M=800-1000KN/t.
4. hubbed flange die-forging forming processing method according to claim 1 and 2, is characterized in that: the heat treatment described in step G adopts gas heat-accumulated type heat-treatment furnace.
5. hubbed flange die-forging forming processing method according to claim 1 and 2, is characterized in that: be provided with indirect vibration isolator in the basis of the Single arm of described blocking and described die forging.
6. hubbed flange die-forging forming processing method according to claim 1 and 2, it is characterized in that: in described die forging, forging die is made up of upper and lower two modules, be fastened in the dovetail groove of tup and die shoe by means of dovetail, drift and key block, described dovetail: module is fixed on tup or anvil block, makes dovetail bottom surface and tup or anvil block bottom surface fit tightly; Described drift: module is located at left and right directions; Described key block: module is located at fore-and-aft direction.
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Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105013994A (en) * | 2015-08-13 | 2015-11-04 | 中国兵器工业第五九研究所 | Streamline control forming method of complex and important parts |
| CN106624625A (en) * | 2016-11-18 | 2017-05-10 | 江苏力野精工科技有限公司 | Flange plate processing method |
| CN106825376A (en) * | 2017-01-23 | 2017-06-13 | 温州电泰阀门有限公司 | A kind of valve body forging technology |
| CN107186444A (en) * | 2017-06-28 | 2017-09-22 | 江阴普洋法兰有限公司 | A kind of hubbed flange processing technology |
| CN108480535A (en) * | 2018-02-02 | 2018-09-04 | 陕西斯瑞新材料股份有限公司 | A kind of manufacturing method of CuNiFe alloys neck welding method orchid |
| CN109093040A (en) * | 2018-07-23 | 2018-12-28 | 江阴市澄东锻造有限公司 | A kind of flange forging method of two phase stainless steel F53 |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105013994A (en) * | 2015-08-13 | 2015-11-04 | 中国兵器工业第五九研究所 | Streamline control forming method of complex and important parts |
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| CN108480535A (en) * | 2018-02-02 | 2018-09-04 | 陕西斯瑞新材料股份有限公司 | A kind of manufacturing method of CuNiFe alloys neck welding method orchid |
| CN108480535B (en) * | 2018-02-02 | 2019-08-23 | 陕西斯瑞新材料股份有限公司 | A kind of manufacturing method of CuNiFe alloy neck welding method orchid |
| CN109093040A (en) * | 2018-07-23 | 2018-12-28 | 江阴市澄东锻造有限公司 | A kind of flange forging method of two phase stainless steel F53 |
| CN111037243B (en) * | 2018-10-11 | 2021-06-11 | 上海汽车变速器有限公司 | Manufacturing method of parking gear of gearbox |
| CN111037243A (en) * | 2018-10-11 | 2020-04-21 | 上海汽车变速器有限公司 | Manufacturing method of parking gear of gearbox |
| CN109648266A (en) * | 2018-12-29 | 2019-04-19 | 山东腾达紧固科技股份有限公司 | A kind of rectangle adjusting nut processing technology |
| CN109648266B (en) * | 2018-12-29 | 2022-02-08 | 山东腾达紧固科技股份有限公司 | Rectangular adjusting nut machining process |
| CN111069493A (en) * | 2019-12-03 | 2020-04-28 | 东台市润丰法兰制造有限公司 | Neck-equipped welding neck flange |
| CN113118351A (en) * | 2019-12-31 | 2021-07-16 | 上海新闵重型锻造有限公司 | Multi-way pipe fitting forging method |
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| CN104785706B (en) | 2017-03-15 |
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Effective date of registration: 20230627 Address after: Qinghe Road Guangzhou city Guangdong province 511450 Panyu District Shiji Town Patentee after: PANYU CHU KONG STEEL PIPE Co.,Ltd. Address before: 222006 Room 401, Comprehensive Guild Hall, Xuwei New District, Haidi Road, Xuwei New District, Lianyungang City, Jiangsu Province Patentee before: LIANYUNGANG PEARL RIVER PETROCHEMICAL TUBE Co.,Ltd. |