CN107626868B - Hourglass-shaped metal grading construction forming method - Google Patents
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Abstract
The invention discloses a method for constructing and forming hourglass-shaped metal in a grading manner, which is characterized by comprising the following steps of firstly constructing at one stage by using a conventional construction method to obtain a blank, and further forging the blank into a round table or square table shape to be used as a blank element constructed at the next stage; then, N-level construction is carried out, and the two blank elements are stacked together to form an hourglass shape on the whole; encapsulating the two blank elements stacked in the hourglass shape into an hourglass-shaped preform; welding the interface between the two blank elements by forge welding to form an hourglass-shaped preform into a blank; further forging the blank into a circular table or square table shape as a blank element constructed at the level of N + 1; and repeating the steps to realize multi-stage construction and prepare a larger blank. The middle of the hourglass shape is small in size, the upper end and the lower end of the hourglass shape are large in size, and the small-sized middle section is preferentially deformed in the deformation process, so that large deformation at the middle interface can be achieved under small pressure.
Description
Technical Field
The invention relates to a metal material manufacturing method, in particular to a processing method for realizing the forming of a metal or metal-based material by an hourglass-shaped grading construction mode. The method is not only suitable for homogeneous material homogenization manufacture, but also suitable for heterogeneous material composite manufacture.
Background
Metal materials are the most indispensable materials in human historical development, and because of the characteristics of unique low price, toughness, durability and the like, metals always dominate the modern material industry. After thousands of years of accumulation, people have mastered a complete set of well-developed metal material production technology, for example, the traditional steel production is subjected to smelting, casting, pressure processing and heat treatment procedures, and the product has stable quality and low price. The metal matrix composite material which appears in recent years combines the advantages of metal materials and non-metal materials, has the characteristics of small specific gravity, high specific strength and the like, and further widens the application range of the metal materials.
The bonding strength of a composite interface in some key fields is high, and the traditional explosion cladding mode has microscopic defects on the interface due to pressure cladding at normal temperature, so that the requirements are difficult to meet, and a new metal cladding method which is more reliable and safer needs to be developed.
A metal construction forming method is an additive manufacturing method for manufacturing a large metal blank by using a plurality of metal blanks with smaller volumes as construction elements. The method achieves the purpose of manufacturing a large forging by using a smaller casting blank, forging blank or rolling blank through the steps of preparing a plurality of elements, stacking the elements into a preset shape, packaging the elements stacked into the preset shape into a prefabricated blank, welding interfaces among the elements into a blank through forge welding, and the like. However, during the construction blank manufacturing process, there is a high probability of rejection due to vacuum breaking at the interface between elements caused by incidental factors such as interface contamination or failure of the weld. For an ultra-large forging with the thickness of more than 100t, the loss of the whole scrapped forging caused by the failure of a single interface is huge, and the risk needs to be avoided by an effective method. And because the total weight of the blank is too large, the pressure required by forging needs to be reduced by an effective means.
Disclosure of Invention
The invention aims to provide an hourglass-shaped grading construction forming method for preparing large metal materials or composite metal materials. The forge welding is a process of realizing metallurgical connection by fully welding interfaces through atomic diffusion among different elements in the high-temperature forging process. After the conventional construction process is completed, forging the blank into a circular truncated cone or square truncated cone shape to obtain a blank element. After the surface processing and cleaning are carried out on the blank elements, the two blank elements are packaged together to form an hourglass-shaped prefabricated blank, the inside of an interface is kept in a high vacuum state, and then a forging and welding process which is characterized by large upsetting deformation is applied to combine the two blank elements together to form the blank. The blank can be forged into a circular table or square table-shaped blank element again, and the process of forge welding two circular table or square table-shaped blank elements into a larger blank is repeated for many times, wherein each construction is called as a first-stage. After multi-stage construction, the manufacture of ultra-large forgings can be realized.
The invention discloses a method for constructing and forming an hourglass-shaped metal in a grading manner, which is characterized by comprising the following steps of:
one-level construction and N-level construction, wherein N is more than or equal to 2,
the first-level construction comprises the following steps:
preparing a plurality of elements;
stacking a plurality of elements into a cylinder or a cuboid;
packaging a plurality of elements stacked in a cylindrical or rectangular parallelepiped shape into a preform;
welding interfaces among a plurality of blank elements by forge welding to prepare a blank from the prefabricated blank, further forging the blank into a circular table or square table shape to be used as a blank element constructed at the next stage, wherein the cross section area of one end of a large plane of the circular table or square table shaped blank is larger than that of one end of a small plane;
the N-level construction comprises the following steps:
stacking two round table or square table-shaped blank elements formed by N-1 level construction together, so that one ends of small planes with smaller cross section areas are in contact with each other to form an hourglass shape on the whole; encapsulating the two blank elements stacked in the hourglass shape into an hourglass-shaped preform;
welding the interface between the two blank elements by forge welding to form an hourglass-shaped preform into a blank;
further forging the blank obtained by forge welding into a round table or square table shape as a blank element constructed at the level of N + 1;
and repeating the step of N-level construction to prepare a larger blank, and forging the blank to the size of the final forging piece after the weight of the blank reaches the target weight.
The technical scheme of the invention is as follows:
an hourglass-shaped metal grading construction forming method comprises the following steps:
first, a blank element is prepared by using a conventional construction method: a plurality of small-specification metal blanks (casting blanks, forging blanks or rolling blanks) are stacked and then packaged in vacuum, and then a forge welding process which is characterized by thick upsetting deformation is applied to the small-specification metal blanks, so that the small-specification metal blanks are combined together to form a blank. And further forging the blank into a circular truncated cone shape or a square truncated cone shape to obtain a blank element. The cross section area of one end of the large plane of the round table or square table-shaped blank is larger than that of one end of the small plane;
then, the blank element is constructed and sealed into a prefabricated blank: one ends of two small planes with smaller cross section areas of the circular truncated cone-shaped or square truncated cone-shaped blank elements are mutually contacted, the two small planes are stacked into a large-size cuboid or cylindrical hourglass shape, the constructed blanks are integrally packaged into a box by adopting a cheap metal plate, and the interior of the box is vacuumized; or the interface between the two elements is encapsulated by adopting a vacuum welding mode; the encapsulated blank is referred to as an hourglass-shaped preform;
the hourglass shaped preform is then forge welded into a blank: heating the packaged hourglass-shaped preform to a specified temperature, discharging, forging on a hydraulic press, and implementing a measure of upsetting and large deformation to fully weld the interface, so that metallurgical connection is realized to form an integrated blank;
further forging the blank to prepare a blank element, and repeating the construction process: and further forging the blank which is forged and welded into a whole into a round table or square table shape. And (3) taking the circular truncated cone or square truncated cone-shaped blank as a blank element, repeating the construction process of manufacturing the blank element into the blank, wherein each repeated construction process is called as a first-stage until the weight of the blank reaches the target weight.
And finally forming a device: and (3) further forming the blank by adopting pressure processing modes such as forging, rolling and the like, and accurately forming the blank into the final specification and size by adopting a machining mode.
The method comprises the following specific steps:
firstly, manufacturing a round table or square table-shaped blank element by using a conventional construction method;
secondly, processing and cleaning the surface of a blank element;
thirdly, stacking the two blank elements into an hourglass shape;
fourthly, packaging the stacked blank elements to enable each contact interface to be in a vacuum state;
fifthly, heating the encapsulated hourglass-shaped prefabricated blank before forging;
sixthly, upsetting the hourglass-shaped prefabricated blank to obtain a blank;
seventhly, forging the blank into a circular table or square table shape to obtain a blank element, and repeating the processes from the second step to the sixth step until the weight of the blank reaches the target weight;
and step eight, machining and forming the blank to the final specification and size.
In the first step of the hourglass-shaped metal grading construction forming method, a conventional construction process is used, a metal blank is cut to prepare a plurality of elements, the surface of the elements is processed and cleaned, the elements are stacked into a cylinder or a cuboid, the elements are packaged into a prefabricated blank, and the prefabricated blank is forged and welded to prepare a blank, wherein the process is called as first-stage construction. And further forging the blank into a circular truncated cone shape or a square truncated cone shape to obtain a blank element. The cross section area of one end of the large plane of the round table or square table-shaped blank is larger than that of one end of the small plane. The inclination angle of the side surface of the circular truncated cone or the square table relative to the axis is 0-30 degrees, the inclination angle of the side surface can be kept consistent all the time and can also be changed continuously, if the inclination angle of the side surface of the circular truncated cone or the square table is gradually reduced from one end of a large plane to one end of a small plane and finally reduced to 0 degree, and the small planes of the two blank elements are in smooth transition relative to the stacked contact interface. The ratio of the height of each blank element to the maximum width/length/diameter does not exceed 1.5: 1, and upsetting deformation is convenient to implement.
In the second step of the hourglass-shaped metal grading construction forming method, the surfaces of the blank elements are polished by using an angle grinder and a steel brush, oxide scales are removed, and the surfaces are machined by using a milling machine if necessary. And then, cleaning the surface by using organic solvents such as acetone, alcohol and the like, so as to ensure high cleanness of the surface and expose fresh metal.
In the third step of the hourglass-shaped metal grading construction forming method, the small plane ends with smaller cross section areas of two round table or square table-shaped blank elements are mutually contacted and stacked into a large-size cuboid or cylindrical hourglass shape, so that the edges are aligned, and the ratio of the total height to the maximum width/length/diameter after stacking is not more than 3: 1.
In the fourth step of the hourglass-shaped metal grading construction forming method, the stacked blank elements are integrally packaged into a box by adopting a low-price metal plate, a vacuumizing interface is reserved in the box body, and the interface is blocked after the interior of the box is vacuumized; or the stacked blank elements are integrally placed in a vacuum chamber, and then the interface between the two elements is packaged in a vacuum welding mode, wherein the welding depth of the packaging interface is 10-50 mm. After the encapsulation an hourglass shaped preform is obtained.
In the fifth step of the hourglass-shaped metal grading construction forming method, the welded prefabricated blank is sent into a heating furnace to be heated, wherein the heating temperature is 0.8-0.9Tm, Tm is the melting point of the material and is measured in degrees centigrade. Preferably the temperature is 0.85 Tm.
In the sixth step of the hourglass-shaped metal grading construction forming method, the heated hourglass-shaped prefabricated blank is horizontally placed on an operating platform of a forging press, and an upsetting plate is adopted to upset the blank along the height direction (namely the direction vertical to an interface); and (3) pressing down 10-50% of the total height of the blank, wherein the process is called forge welding, and the blank is obtained after the forge welding is finished, and the process is called second-stage construction. During the forging process, if the interface between the two blank elements fails to fully weld together, the two blank elements are separated and forged back to the dimensions of the blank elements in the first step to re-perform the second stage build.
And in the seventh step of the hourglass-shaped metal grading construction forming method, further forging the blank obtained in the sixth step into a circular table or square table shape to obtain a blank element. And (3) performing surface machining, cleaning, stacking, packaging and forge welding on the two blank elements with the same size again, namely repeating the process from the second step to the sixth step, wherein the process is called as third-level construction. This process can be repeated multiple times, each repetition of the construction being referred to as a stage. The weight of the blank after each construction is 2 times of that of the blank element before the construction, and multi-stage construction is carried out until the weight of the blank reaches the target weight.
In the eighth step of the hourglass-shaped metal grading construction forming method, the blank constructed in multiple stages is further formed by forging, rolling and other pressure processing modes, and is precisely formed into the final specification and size by adopting a machining mode.
The invention breaks through the traditional thinking that the base metal of the metal device is larger than the base metal, uses a small metal blank with better quality and lower cost to construct and form, and has the following advantages and beneficial effects:
1. and the homogenization manufacturing of large-size metal devices is realized. A plurality of metal blanks with smaller volumes are used as construction elements, the component uniformity of the metal blanks is far better than that of a large metal blank integrally cast in the prior art due to high solidification speed, and large-size metal devices constructed on the basis do not have obvious macrosegregation.
2. Realizing the densification manufacturing of large-size metal devices. A plurality of metal blanks with smaller volumes are used as construction elements, and because the solidification speed is high, the simultaneous solidification can be almost realized, and the concentrated shrinkage cavities in the blanks are less loose. After deformation, heat preservation and multidirectional forging of the welding interface, the compactness is higher than that of a forging piece made of a traditional integral casting blank.
3. Realizing the purification manufacture of large-size metal devices. A plurality of metal blanks with smaller volumes are used as construction elements, and the preparation cost and difficulty are low, so that the purification of the elements can be realized by adopting various flexible refining methods, and the purity of large-size metal devices constructed on the basis is higher than that of forgings made of traditional integral casting blanks.
4. Realizing low-cost manufacture of large-size metal devices. The metal blank with small volume can be prepared by adopting large production means such as continuous casting and the like, and the manufacturing cost is far lower than that of a die casting means which is required to be adopted for preparing the metal blank with large volume, so the manufacturing cost can be greatly reduced. In addition, continuous casting billets are used as construction elements, riser and nozzle loss of traditional steel ingots is avoided, and the utilization rate of materials can be improved by more than 15%.
5. Realize the clean and stable manufacture of large-size metal devices. The traditional die casting method for preparing the metal blank needs to manually prepare a die, a pouring gate and a heat insulation material, and simultaneously, a riser heating agent and a covering agent after pouring have great environmental pollution. By adopting the hourglass-shaped metal grading construction forming method, the process can be fully automated, the labor environment can be improved, the influence of human factors is reduced, and the product quality is more stable.
6. High-reliability graded manufacturing of ultra-large components is realized. In the traditional construction method, a plurality of metal blanks are directly constructed, and the possibility of scrapping caused by interface vacuum breaking due to accidental factors such as interface pollution or welding seam failure in the blank construction process is high. For example, for an ultra-large forging with the weight of more than 100t, a continuous casting billet is used for construction by adopting a traditional construction method, the number of stacked layers of the continuous casting billet exceeds 10, and the failure of a single interface between any two layers can cause the whole forging to be scrapped, so that the loss is huge. The grading construction forming method can realize gradual size reduction, only a plurality of interfaces exist in the blank in the first-stage construction process, only one interface exists in the subsequent multi-stage construction process at each time, and the risk of integral scrapping of the forge piece caused by interface vacuum breaking can be effectively reduced.
7. And the small-pressure manufacturing of the ultra-large component is realized. The traditional construction method is to directly construct a plurality of metal blanks, and the prefabricated blank is cylindrical or cuboid, so that the pressure of a press required by deformation is large. By adopting the hourglass-shaped metal grading construction method, the middle of the hourglass shape is small in size, the upper end and the lower end of the hourglass shape are large in size, and the small-sized middle section is preferentially deformed in the deformation process, so that the large deformation of the middle interface can be realized under small pressure, the interface metallurgical bonding between metal elements is realized, and the pressure required by the construction and forming of the ultra-large member is reduced.
Drawings
FIGS. 1a to 1h are process flow diagrams of the present invention, wherein FIG. 1a shows a preform obtained using a conventional build-up process; FIG. 1b is a blank obtained by forge welding the preform into a circular truncated cone or square truncated cone, and obtaining a blank element; FIG. 1c shows a blank element surface being machined flat to expose fresh metal and cleaned; FIG. 1d shows the sealing around the interface between the elements of the blank in a vacuum environment to obtain an hourglass shaped preform; FIG. 1e shows the hourglass shaped preform being placed into a high temperature furnace for heating; FIG. 1f shows upsetting with an upsetting plate on a forging press along the height of the hourglass-shaped preform; FIG. 1g shows the upset deformation in place, causing the defects to weld together sufficiently to obtain a slug; FIG. 1h shows the blank is further forged, machined to final part shape and size.
Fig. 2 is a schematic diagram of a construction process in embodiment 1 of the present invention, in which a square-table-shaped blank element used in a second-stage construction is prepared in a conventional construction process in the first-stage construction, the two square-table-shaped blank elements obtained in the first-stage construction are made into square-table-shaped blank elements used in a third-stage construction by using the method of the present invention, and the two square-table-shaped blank elements obtained in the second-stage construction are prepared into a larger blank by using the method of the present invention in the third-stage construction.
Fig. 3 is a schematic diagram of a construction process in embodiment 2 of the present invention, in which a truncated cone-shaped blank primitive used in a second-stage construction is prepared in a conventional construction process in the first-stage construction, the truncated cone-shaped blank primitive obtained in the first-stage construction is made into a truncated cone-shaped blank primitive used in a third-stage construction by using the method of the present invention in the second-stage construction, and the two truncated cone-shaped blank primitives obtained in the second-stage construction are prepared into a larger-sized blank by using the method of the present invention in the third-stage construction.
Detailed Description
FIGS. 1a to 1h are process flow diagrams of the present invention, wherein FIG. 1a shows a preform obtained using a conventional build-up process; FIG. 1b is a blank obtained by forge welding the preform into a circular truncated cone or square truncated cone, and obtaining a blank element; FIG. 1c shows a blank element surface being machined flat to expose fresh metal and cleaned; FIG. 1d shows the sealing around the interface between the elements of the blank in a vacuum environment to obtain an hourglass shaped preform; FIG. 1e shows the hourglass shaped preform being placed into a high temperature furnace for heating; FIG. 1f shows upsetting with an upsetting plate on a forging press along the height of the hourglass-shaped preform; FIG. 1g shows the upset deformation in place, causing the defects to weld together sufficiently to obtain a slug; FIG. 1h shows the blank is further forged, machined to final part shape and size.
Fig. 2 is a schematic diagram of a construction process in embodiment 1 of the present invention, in which a square-table-shaped blank element used in a second-stage construction is prepared in a conventional construction process in the first-stage construction, the two square-table-shaped blank elements obtained in the first-stage construction are made into square-table-shaped blank elements used in a third-stage construction by using the method of the present invention, and the two square-table-shaped blank elements obtained in the second-stage construction are prepared into a larger blank by using the method of the present invention in the third-stage construction.
Example 1
The target product of this example is a 316 stainless steel ring. Firstly, a continuous casting mode is adopted, a continuous casting slab with the width of 1000mm and the thickness of 300mm is cast, and the steel grade is 316H. Then cutting a continuous casting billet element with the length of 1000mm, processing and cleaning the continuous casting billet element, and sealing and welding the continuous casting billet element into a prefabricated blank in a vacuum chamber. The preform was forge welded and further forged to obtain a 10t grade blank element. And (3) carrying out surface machining, cleaning, stacking, packaging, forge welding and further forging on 4 pieces of 10 t-grade blank elements to obtain 2 pieces of 20 t-grade blank elements. And (3) carrying out surface machining, cleaning, stacking, packaging and forge welding on 2 20 t-grade blank elements to obtain 1 40 t-grade blank. And finally forging the blank into an annular member. The method comprises the following specific steps:
in a first step, a blank element is fabricated using conventional construction methods. Cutting 16 continuous casting billets with the specification of 1000 multiplied by 300mm, and sealing and welding the processed and cleaned continuous casting billets into a preformed blank with the specification of 1000 multiplied by 1200mm in a vacuum chamber every 4 blocks. And (3) forging the blank into a square table shape with a large plane of 1240X 1240mm, a small plane of 870X 870mm, a height of 1050mm and a constant side inclination angle, wherein the blank is a 10t class blank element. A total of 4 pieces of grade 10t blank elements were obtained.
And secondly, processing and cleaning the surface to be welded. The surface of a 10 t-grade blank element is processed by a planer type milling machine, and then acetone is adopted for cleaning, so that the surface is guaranteed to be highly clean, and fresh metal is exposed.
And thirdly, stacking the 10 t-grade blank elements. Two 10t grade blank elements were stacked to give a top and bottom surface 1240 x 1240mm, a central narrowest portion 870 x g70mm, an hourglass shape with a height 2100mm and a weight of about 20 t.
Fourthly, vacuum electron beam welding is carried out on the 10 t-grade blank element. And (3) carrying out vacuum electron beam welding on the periphery of the stacked 10 t-grade blank element, wherein the welding depth is 50mm, and obtaining a 20 t-grade prefabricated blank after the welding is finished.
And fifthly, heating the 20 t-grade preform before forging. And (3) feeding the welded prefabricated blank into a heating furnace for heating, wherein the heating temperature is 1200 ℃.
And sixthly, upsetting the 20 t-grade preform. And placing the heated 20 t-grade preform on an operation platform of a forging press, wherein the height direction of the 20 t-grade preform is along the vertical direction. Upsetting the prefabricated blank along the height direction by adopting an upsetting plate, and pressing down the total height of the prefabricated blank by 50 percent. And obtaining a 20t grade blank after the deformation is finished. The blank is forged into a square table with a large plane of 1550X 1550mm, a small plane of 1085X 1085mm and a height of 1320mm to form a 20 t-grade blank element. A total of 2 pieces of class 20t blank elements were obtained.
And seventhly, manufacturing a 40 t-grade blank. And (3) carrying out surface machining, cleaning, stacking and packaging on the 2 20 t-grade blank elements to obtain a 40 t-grade preform. And (4) forge welding the prefabricated blank into a 40 t-grade blank, namely repeating the processes from the second step to the sixth step.
And eighthly, forging and forming the 40 t-grade blank to the size of a final forging piece, wherein the forging piece is annular, the inner diameter of the forging piece is 1030mm, the outer diameter of the forging piece is 2630mm, and the height of the forging piece is 1000 mm.
Fig. 3 is a schematic diagram of a construction process in embodiment 2 of the present invention, in which a truncated cone-shaped blank primitive used in a second-stage construction is prepared in a conventional construction process in the first-stage construction, the truncated cone-shaped blank primitive obtained in the first-stage construction is made into a truncated cone-shaped blank primitive used in a third-stage construction by using the method of the present invention in the second-stage construction, and the two truncated cone-shaped blank primitives obtained in the second-stage construction are prepared into a larger-sized blank by using the method of the present invention in the third-stage construction.
Example 2
The target product of this embodiment is a rotor forging. Firstly, a continuous casting method is adopted to cast a continuous casting slab with the width of 1600mm and the thickness of 300mm, and the steel grade is 16 Mn. Then cutting a continuous casting billet element with the length of 1600mm, processing and cleaning the continuous casting billet element, and sealing and welding the continuous casting billet element into a prefabricated blank in a vacuum chamber. The preform was forge welded and further forged to obtain a class 40t blank element. And (3) carrying out surface machining, cleaning, stacking, packaging, forge welding and further forging on 4 pieces of 40 t-grade blank elements to obtain 2 pieces of 80 t-grade blank elements. And (3) carrying out surface machining, cleaning, stacking, packaging and forge welding on 2 80 t-grade blank elements to obtain 1 160 t-grade blank. And finally forging the blank into the rotor. The method comprises the following specific steps:
in a first step, a blank element is fabricated using conventional construction methods. 28 continuous casting billets with the specification of 1600 multiplied by 300mm are cut, and after the continuous casting billets are processed and cleaned, every 7 continuous casting billets are stacked and sealed in a vacuum chamber to form a prefabricated blank with the specification of 1600 multiplied by 2100 mm. And forging the blank into a truncated cone shape with a large plane of phi 2250mm, a small plane of phi 1650mm and a height of 1750mm, wherein the side surface of the blank close to the small plane is in circular arc transition, and the radius of the circular arc is 1000 mm. The blank is a class 40t blank element. A total of 4 pieces of class 40t boule cells were obtained. And secondly, processing and cleaning the surface to be welded. The surface of a 40 t-level blank element is processed by a planer type milling machine, and then acetone is adopted for cleaning, so that the surface is guaranteed to be highly clean, and fresh metal is exposed.
And thirdly, stacking the 40 t-grade blank elements. Two 40 t-grade blank elements are stacked to form an hourglass shape with the top surface and the bottom surface phi 2250mm, the thinnest part phi 1650mm in the middle and the height 3500mm, and the thinnest part in the middle of the hourglass has a circular arc transition with the radius of 1000mm and the weight is about 80 t.
And fourthly, performing vacuum electron beam welding on the 40 t-grade blank element. And (3) carrying out vacuum electron beam welding on the periphery of the stacked 40 t-grade blank element, wherein the welding depth is 50mm, and obtaining an 80 t-grade prefabricated blank after the welding is finished.
And fifthly, heating the 80 t-grade preform before forging. And (3) feeding the welded prefabricated blank into a heating furnace for heating, wherein the heating temperature is 1200 ℃.
And sixthly, upsetting the 80 t-grade preform. And placing the heated preforms of 80t level on an operation platform of a forging press, wherein the height direction of the preforms of 80t level is along the vertical direction. Upsetting the prefabricated blank along the height direction by adopting an upsetting plate, and pressing down the total height of the prefabricated blank by 50 percent. And obtaining an 80t grade blank after the deformation is finished. Forging the blank into a circular truncated cone shape with a large plane phi 2900mm, a small plane phi 2250mm and a height of 2000mm, wherein the side surface close to the small plane is in circular arc transition, and the radius of the circular arc is 1500mm, so as to obtain an 80 t-grade blank element. A total of 2 pieces of class 80t boule cells were obtained.
And seventhly, manufacturing a 160 t-grade blank. And (3) carrying out surface machining, cleaning, stacking and packaging on the 2 blocks of 80 t-grade blank elements to obtain 160 t-grade preforms. And (4) forge welding the preform to obtain a 160t grade blank, namely repeating the processes from the second step to the sixth step.
And eighthly, forging and forming the 160 t-grade blank to the size of a final forging, wherein the forging is a rotor forging, the total length is 9000mm, the maximum diameter is 3000mm, and the minimum diameter is 700 mm.
Claims (11)
1. An hourglass-shaped metal grading construction forming method is characterized by comprising the following steps:
one-level construction and N-level construction, wherein N is more than or equal to 2,
the first-level construction comprises the following steps:
preparing a plurality of elements;
stacking a plurality of elements into a cylinder or a cuboid;
packaging a plurality of elements stacked into a cylinder or a cuboid into a prefabricated blank;
welding interfaces among a plurality of blank elements by forge welding to prepare a blank from the prefabricated blank, further forging the blank into a circular table or square table shape to be used as a blank element constructed at the next stage, wherein the cross section area of one end of a large plane of the circular table or square table shaped blank is larger than that of one end of a small plane;
the N-level construction comprises the following steps:
stacking two round table or square table-shaped blank elements formed by N-1 level construction together, so that one ends of small planes with smaller cross section areas are in contact with each other to form an hourglass shape on the whole;
encapsulating the two blank elements stacked in the hourglass shape into an hourglass-shaped preform;
welding the interface between the two blank elements by forge welding to form an hourglass-shaped preform into a blank;
further forging the blank obtained by forge welding into a round table or square table shape as a blank element constructed at the level of N + 1;
repeating the step of N-level construction to prepare a larger blank, and repeating the construction process until the weight of the blank reaches the target weight, and forging the blank to the size of a final forging piece;
the inclination angle of the square frustum-shaped side surface relative to the axis is greater than or equal to arctan (185/1050) and less than or equal to 30 degrees, and the inclination angle of the circular frustum-shaped side surface relative to the axis is greater than or equal to arctan (300/1750) and less than or equal to 30 degrees.
2. The hourglass-shaped metal grading construction forming method according to claim 1, wherein the inclination angles of the circular truncated cone-shaped or square truncated cone-shaped side surfaces are always kept consistent.
3. The hourglass-shaped metal grading construction forming method according to claim 1, wherein the inclination angle of the truncated cone-shaped or square-truncated-cone-shaped side surface is gradually reduced from the end of the large plane to the end of the small plane and finally is reduced to 0 °.
4. The hourglass-shaped metal stepped build forming process of claim 1 wherein the ratio of height to maximum width/length/maximum diameter of the hourglass shape formed by stacking two blank elements does not exceed 3: 1.
5. The hourglass metal stepped build forming method of claim 1, wherein the hourglass shape is a cuboid or cylindrical hourglass shape.
6. The hourglass metal buildup forming method of claim 1, wherein the step of forming the hourglass preform into a blank by forge welding the interface between the two blank elements comprises heating the preform to a temperature in the range of 0.8 to 0.9Tm, Tm being the melting point of the material in degrees celsius, and then placing the heated hourglass preform on a forging press platen to forge and press the heated hourglass preform to deform the hourglass preform.
7. The hourglass metal could be stepped to build up the shape of claim 6 wherein the deformation is from 10% to 50% of the total length of the hourglass preform in the direction of deformation.
8. The hourglass metal framing forming method of claim 7, wherein the deformation direction is the height direction of the hourglass preform, i.e., the direction perpendicular to the interface between two blank elements.
9. The hourglass metal stepped build forming method of claim 8, wherein during the forging of the hourglass preform to deform the hourglass preform, the deformation is stopped when the cross-sectional area of the hourglass preform is substantially equal from end to center.
10. The metal buildup forming method of claim 1, wherein in performing said N-level buildup step, if the interface between the two green elements fails to fully weld together during the process of welding the interface between the two green elements to form the blank by forge welding, the two green elements can be separated and forged back to the truncated or square-truncated dimensions of the green element at the end of the N-1 level buildup for another N-level buildup.
11. The hourglass-shaped metal grading construction forming method according to claim 6, wherein the heating temperature is 0.85 Tm.
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