CN111496172A - Double-roller rotary forging forming method for thin-wall metal disc - Google Patents

Double-roller rotary forging forming method for thin-wall metal disc Download PDF

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CN111496172A
CN111496172A CN202010296669.5A CN202010296669A CN111496172A CN 111496172 A CN111496172 A CN 111496172A CN 202010296669 A CN202010296669 A CN 202010296669A CN 111496172 A CN111496172 A CN 111496172A
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finished product
semi
double
blank
cone roller
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CN111496172B (en
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朱春东
余中全
周联谱
王琪
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Wuhan University of Technology WUT
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Wuhan University of Technology WUT
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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
    • B21K1/28—Making machine elements wheels; discs
    • B21K1/32—Making machine elements wheels; discs discs, e.g. disc wheels
    • 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 relates to a double-roller rotary forging forming method of a thin-wall metal disc, which comprises the following steps: s1, preparing a semi-finished product: heating and upsetting the blank to form a semi-finished product; s2, positioning of the semi-finished product: heating the semi-finished product to a forming temperature range, then placing the semi-finished product on a mold core, and positioning the heated semi-finished product by the mold core; s3, forming the semi-finished product under the rolling of a double-cone roller: the double-cone roller revolves around the central axis of the main shaft, the female die drives the blank to move upwards in a feeding way, when the workpiece is contacted with the double-cone roller, the double-cone roller starts to rotate under the action of the friction force of the blank, the blank is axially rolled by the double-cone roller, and the blank continues to move upwards in a feeding way along with the female die; s4, finishing the preparation of the finished product: after the blank is rolled to the target height by the double-cone roller, the female die stops feeding upwards, and the double-cone roller continues to revolve for 2-3 circles. The method has the advantages of symmetrical forming load relative to the center, small forming load, long service life of equipment, high material utilization rate, high safety level and the like.

Description

Double-roller rotary forging forming method for thin-wall metal disc
Technical Field
The invention relates to the field of thin-wall metal disc manufacturing, in particular to a double-roller rotary forging forming method of a thin-wall metal disc.
Background
With the improvement of the industrial level and the development of national defense industry, the thin-wall metal disc with large diameter/thickness ratio is more and more widely applied in the fields of petrochemical industry, coal liquefaction, aerospace, deep sea exploration and the like. At present, the metal disc part is mainly formed by open die forging, but when the diameter of the formed metal disc part reaches 500mm, the thin-wall metal disc with large diameter/thickness ratio cannot be formed by the open die forging process. The tonnage of equipment required for forming the thin-wall metal disc with large integral diameter/thickness ratio by using the rotary forging machine is only 10-20 percent of that of a common press machine, and the method provides a novel plastic forming process method for forging and forming the metal disc piece. However, in the common swing rolling forming process, the conical roller is only contacted with a workpiece at one side, and in the forming process, the workpiece is stressed unevenly and asymmetrically at all times, so that the center of the workpiece is easily thinned, even cracked or warped and other defects are easily caused, therefore, the maximum diameter of the metal disc piece which can be formed by the swing rolling forming machine is only 500mm, the service life of the swing spherical chain is short, and the equipment production and maintenance cost is high;
at present, no better forming method exists for a thin-wall metal disc part with the diameter of more than 500mm and the diameter/thickness of 100.
Disclosure of Invention
The invention aims to solve the technical problem of providing a double-roller rotary forging forming method of a thin-wall metal disc, which can form the thin-wall metal disc with the diameter of more than 500mm and the diameter/thickness ratio of 100. Meanwhile, the method has the advantages of symmetrical forming load about the center, small forming load, long service life of equipment, high material utilization rate, high safety level and the like.
The technical scheme adopted by the invention for solving the technical problems is as follows: a double-roller rotary rolling forming method for constructing a thin-wall metal disc comprises the following steps:
s1, preparing a semi-finished product: heating and upsetting the blank to form a semi-finished product;
s2, positioning of the semi-finished product: heating the semi-finished product to a forming temperature range, then placing the semi-finished product on a mold core, and positioning the heated semi-finished product by the mold core to prevent the semi-finished product from generating center deviation during forming;
s3, forming the semi-finished product under the rolling of a double-cone roller: the double-cone roller revolves around the central axis of the main shaft, the female die drives the blank to move upwards in a feeding way, when the workpiece is contacted with the double-cone roller, the double-cone roller starts to rotate under the action of the friction force of the blank, the blank is axially rolled by the double-cone roller, and the diameter of the blank is gradually increased and the height of the blank is gradually reduced along with the continuous upward feeding movement of the female die;
s4, finishing the preparation of the finished product: after the blank is rolled to the target height by the double-cone roller, the female die stops feeding upwards, and the double-cone roller continues to revolve for 2-3 circles, so that the surface of the formed workpiece is rolled into a plane by the double-cone roller, and the preparation of a finished product is finished.
In the method, the specific calculation formula of the height H of the semi-finished product is as follows:
Figure BDA0002452441750000021
in the formula, D0And H0Is the diameter and height of the target workpiece, D1The diameter of the semi-finished product is h, the height of the mold core is lower than that of the female mold1，3mm≤h1Less than or equal to 8 mm; height reduction H before and after blank forming2＝H-H0，H2＝20～40mm。
In the method, the diameter of the mold core is D2，D1×α+2≤D2≤D1×α +4, α is the linear expansion coefficient of metal, α is 1.5 × 10-5/℃。
In the above method, when the diameter D of the target workpiece0When the thickness is less than or equal to 700mm, the feeding speed of the concave die is less than or equal to upsilon and 0.8mm/s1Less than or equal to 1.2mm/s, and the rotating speed n of the upper die1Is 60 to 75 r/min.
In the method, when the diameter 700 of the target workpiece is less than D0When the thickness is less than or equal to 1500mm, the feeding speed of the concave die is less than or equal to upsilon and 1mm/s1Less than or equal to 1.4mm/s, and the rotating speed n of the upper die1Is 60 to 75 r/min.
In the above method, when the diameter of the target workpiece is 1500 < D0When the thickness is less than or equal to 2000mm, the feeding speed of the concave die is less than or equal to upsilon and 1.2mm/s1Less than or equal to 1.6mm/s, and the rotating speed n of the upper die1Is 60 to 75 r/min.
In the method, the forming time t of the semi-finished product in the mould is less than or equal to 1 min.
The double-roller rotary forging forming method of the thin-wall metal disc has the following beneficial effects:
the invention can select the optimal rotating speed of the upper die and the optimal feeding speed of the female die according to the diameter and the height of the target thin-wall metal disc, avoid the defects of center thinning and the like of a workpiece in the forming process by locally thickening the center part of the workpiece, form a thin-wall metal disc part with the diameter larger than 500mm and a large diameter/thickness ratio, and has the advantages of small forming load, symmetrical forming load relative to the center, long service life of the die, high material utilization rate and high safety level of the formed part.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic drawing of the target workpiece dimensions of the present invention.
Fig. 2 is a schematic dimension view of the semi-finished product of the present invention.
Fig. 3 is a schematic view of the mold opening of the present invention.
FIG. 4 is a schematic diagram of the movement of the upper and lower dies during the forming of a workpiece according to the present invention.
Fig. 5 is a schematic view of a finished product after the forming of the workpiece according to the present invention.
Wherein: 1 is a double-cone roller, 2 is a semi-finished product, 3 is a mold core, 4 is a female mold, 5 is a mold base and 6 is a finished product.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
The invention provides a double-roller rotary forging forming method of a thin-wall metal disc, which comprises the following steps:
s1, preparing a semi-finished product 2: the blank is heated and upset to form a semi-finished product 2.
S2, positioning of the semi-finished product 2: and (3) heating the semi-finished product 2 in a high-temperature heating furnace to a forming temperature range, taking out the semi-finished product 2, quickly placing the semi-finished product on a mold core 3, positioning the mold core 3 in a female mold 4, and placing the female mold 4 on a mold base 5. The mold core 3 positions the heated semi-finished product 2 while preventing the semi-finished product 2 from being shifted in center when it is formed.
S3, forming the semi-finished product 2 under the rolling of a double-cone roller 1: the double-cone roller 1 revolves around the central axis of the main shaft, the female die 4 drives the blank to move upwards, when a workpiece is contacted with the double-cone roller 1, the double-cone roller 1 starts to rotate under the action of the friction force of the blank, the blank is axially rolled by the double-cone roller 1, and the diameter of the blank is gradually increased and the height of the blank is gradually reduced along with the continuous upwards feeding movement of the female die 4.
S4, finishing the preparation of the finished product: because the contact area of the double-cone roller 1 and the blank is a spiral surface, after the blank is rolled to a target height by the double-cone roller 1, the female die 4 stops feeding upwards, and the double-cone roller 1 continues to revolve for 2-3 circles, so that the surface of a formed workpiece is rolled into a plane by the double-cone roller 1, and the preparation of a finished product 6 is completed.
Through the steps, the thin-wall metal disc part with a large diameter/thickness ratio is formed.
Furthermore, the forming time t of the blank in the die is less than or equal to 1min, if t is more than 1min, the blank temperature is lower than the forming temperature due to the heat exchange effect with the surrounding environment, the required rolling pressure is extremely high, the rated tonnage of the equipment can be exceeded, the die is easy to damage, and the thin-wall metal disc piece with the required target size cannot be formed.
Further, according to the geometrical relationship when the blank is formed, deducing the stable rolling condition of the blank:
Figure BDA0002452441750000031
in the formula1The feeding speed (mm/S) of the female die 4, n is the rotating speed (r/min) of the upper die, and S is the feeding amount (mm) of the blank material of one revolution of the single conical roller 1 of the upper die. According to the simulation analysis and calculation results of ABAQUS finite element software, the rotating speed n of the upper die is most suitable in the range of 60-75 r/min. Optimum feed speed v of die 41Diameter D of target size formed with blank0(ii) related; when D is present0Not more than 700mm, 0.8mm not more than upsilon1Less than or equal to 1.2 mm; when 700 < D0When the thickness is less than or equal to 1500mm, 1mm is less than or equal to upsilon1Less than or equal to 1.4 mm; when 1500 < D0When the diameter is less than or equal to 2000mm, 1.2mm is less than or equal to upsilon1Less than or equal to 1.6mm, so thatAccording to the diameter D of the target metal disc member0To determine the feed speed of the female die 4.
Further, assume that the reduction in height before and after the blank is formed is H2: diameter D of target disk member0When determined, the optimum feed velocity v1It can also be correspondingly determined that the forming time t of the blank in the die is less than or equal to 1min, and then t and upsilon1Determining the height reduction H before and after forming the blank2This H2Is variable and can be adjusted by controlling the blank forming time and the feeding speed of the female die 42And (5) controlling.
Further, the diameter for any given target workpiece is D0Height of H0And a reduction H in forming height2The diameter of the semi-finished product 2 can be determined according to the equal volume principle. In the same way, the same semi-finished product 2 diameter D is used1By controlling H2Within a proper range, the required target workpiece size can be formed, and the H can be adjusted by controlling the forming time of the blank in the die and the feeding speed of the lower die2And (5) controlling. The method can realize that the same set of die is used for producing target metal disc parts with different diameters and heights within a certain range.
Further, the diameter of the mould core 3 is dependent on the diameter D of the semifinished product 21To be determined. Diameter D when the target size is0Within a certain range, the diameter D of one semifinished product 2 can be shared1By controlling H2To shape the target workpiece. Diameter D of the bound target size0The speed relationship with the female die 4 can be realized by designing three sets of female dies 4 respectively used for forming D of the target disc part0≤700mm，700＜D0≤1500mm，1500＜D0Less than or equal to 2000 mm. The full-diameter size forming of the metal disc part with the diameter of less than 2m can be realized. Thus, when the diameter of the target size is within a certain range, there will be a certain diameter D of the semi-finished product 21The diameter of the mold core 3 is designed to be D2D is less than or equal to 2mm2-D1Less than or equal to 4mm, and forming the target workpiece. The effect of this design size lower mold core 3 has two: firstly, the mold core 3 heatsThe latter semi-finished product 2 is positioned. Secondly, the mold core 3 can prevent the semi-finished product 2 from generating center deviation during forming.
Furthermore, when the semi-finished product 2 is formed, the center of the workpiece is subjected to tangential and radial tensile stress and axial compressive stress, only part of the upper surface of the workpiece is in contact with the upper die at each moment in the rotary milling process, the swinging of the swinging heads of different parts of the periphery of the workpiece alternately generates plastic deformation, and the part close to the center of the workpiece is stable in stress state, generates continuous bidirectional extension and unidirectional shortening deformation, so that the center of the workpiece is thinner than other parts along with the accumulation of deformation, and the blank can generate defects such as center thinning and even cracking. By designing the height of the mold core 3 to be h lower than that of the female mold 41The workpiece center is locally thickened, under the combined action of the lower die and the local thickening of the workpiece center, the tensile stress of the workpiece center can be reduced to form a region which is difficult to deform, and the defects of thinning of the workpiece center and the like in the rolling process can be avoided. H is not less than 3mm1The reason why the diameter is less than or equal to 8mm is that: h is1Too small to avoid the center thinning phenomenon, h1Too large results in waste of material.
Further, the diameter of the target workpiece is D0Height of H0When D is present0Within a certain range, the same D can be used for the diameter of the semifinished product 21According to the principle that the volume is equal before and after forming, a calculation formula of the height H of the semi-finished product 2 can be deduced:
Figure BDA0002452441750000041
in the formula, D0And H0Is the diameter and height of the target workpiece, D1Is the diameter of the semi-finished product 2, h1The height of the mold core 3 is lower than that of the concave mold 4.
Compared with the prior art, the invention mainly has the following advantages:
first, the present invention can determine the optimum rotation speed of the upper mold and the optimum feed speed of the female mold 4 according to the diameter range of the target disc member.
Secondly, the invention can design three sets of female dies 4 to form any thin-wall metal disc piece with the diameter less than 2m and the diameter/thickness ratio larger.
Thirdly, the diameter of the mold core 3 used in the invention is 2-4 mm larger than that of the workpiece, the mold core 3 can position the heated semi-finished product 2, and the semi-finished product 2 can be prevented from generating center deviation during forming.
Fourthly, the mold core 3 used in the invention is a cylinder, the height of the mold core 3 is 3-8 mm lower than that of the female mold 4, the workpiece is locally thickened due to the size, under the combined action of the female mold 4, the stress state of the center of the workpiece can be improved, the tensile stress borne by the center of the workpiece is reduced, the workpiece becomes an area difficult to deform, and the defects of center thinning or cracking and the like of the workpiece in the pendulum rolling process are avoided.
Fifthly, the invention can form the thin-wall metal disc piece with the diameter of more than 500mm and the large diameter/thickness ratio of the workpiece, and has high material utilization rate and high safety level of the formed piece.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.

Claims (7)

1. A double-roller rotary forging forming method of a thin-wall metal disc is characterized by comprising the following steps:
s1, preparing a semi-finished product: heating and upsetting the blank to form a semi-finished product;
s2, positioning of the semi-finished product: heating the semi-finished product to a forming temperature range, then placing the semi-finished product on a mold core, and positioning the heated semi-finished product by the mold core to prevent the semi-finished product from generating center deviation during forming;
s3, forming the semi-finished product under the rolling of a double-cone roller: the double-cone roller revolves around the central axis of the main shaft, the female die drives the blank to move upwards in a feeding way, when the workpiece is contacted with the double-cone roller, the double-cone roller starts to rotate under the action of the friction force of the blank, the blank is axially rolled by the double-cone roller, and the diameter of the blank is gradually increased and the height of the blank is gradually reduced along with the continuous upward feeding movement of the female die;
s4, finishing the preparation of the finished product: after the blank is rolled to the target height by the double-cone roller, the female die stops feeding upwards, and the double-cone roller continues to revolve for 2-3 circles, so that the surface of the formed workpiece is rolled into a plane by the double-cone roller, and the preparation of a finished product is finished.
2. The method for forming the thin-walled metal disc by twin-roll swing forging according to claim 1, wherein the specific calculation formula of the height H of the semi-finished product is as follows:
Figure FDA0002452441740000011
in the formula, D0And H0Is the diameter and height of the target workpiece, D1The diameter of the semi-finished product is h, the height of the mold core is lower than that of the female mold1，3mm≤h1Less than or equal to 8 mm; height reduction H before and after blank forming2＝H-H0，H2＝20～40mm。
3. The method of claim 1, wherein the die core has a diameter D2，D1×α+2≤D2D1 ×α +4 is not more than D α is the linear expansion coefficient of metal, α is 1.5 × 10-5/℃。
4. The method of claim 1, wherein the diameter D of the target workpiece is determined by the method0When the thickness is less than or equal to 700mm, the feeding speed of the concave die is less than or equal to upsilon and 0.8mm/s1Less than or equal to 1.2mm/s, and the rotating speed n of the upper die1Is 60 to 75 r/min.
5. The method of claim 1, wherein the target workpiece diameter is 700 < D0When the thickness is less than or equal to 1500mm, the feeding speed of the concave die is less than or equal to upsilon and 1mm/s1Less than or equal to 1.4mm/s, and the rotating speed n of the upper die1Is 60 to 75 r/min.
6. The method of claim 1, wherein the target workpiece diameter is 1500 < D0When the thickness is less than or equal to 2000mm, the feeding speed of the concave die is less than or equal to upsilon and 1.2mm/s1Less than or equal to 1.6mm/s, and the rotating speed n of the upper die1Is 60 to 75 r/min.
7. The method for forming a thin-walled metal disc by twin-roll swing forging according to claim 1, wherein the forming time t of the semi-finished product in the die is less than or equal to 1 min.
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Cited By (2)

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Publication number Priority date Publication date Assignee Title
CN113579645A (en) * 2021-07-06 2021-11-02 武汉理工大学 Forming method of large-diameter functionally-graded thin-wall circular ring part based on double-roller rotary forging
CN114789325A (en) * 2022-03-09 2022-07-26 武汉理工大学 Double-roller rotary forging forming method for constructing large-diameter thin-wall composite metal disc

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CN114789325A (en) * 2022-03-09 2022-07-26 武汉理工大学 Double-roller rotary forging forming method for constructing large-diameter thin-wall composite metal disc

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