CN112676519A - Large-specification electric upsetting method with gradient change of electrode resistivity and anvil electrode - Google Patents
Large-specification electric upsetting method with gradient change of electrode resistivity and anvil electrode Download PDFInfo
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Abstract
The invention discloses a large-scale electric upsetting method with gradient change of electrode resistivity, under the action of electric upsetting, a rod blank gradually and radially increases to form garlic bulbs; when the garlic bulbs radially increase to the size that the garlic bulbs tend to axially sink, taking the annular belt area where the garlic bulb edges are in contact with the anvil electrode as an annular restraining area on the anvil electrode; increasing the resistivity of the annular suppression region to locally reduce the current density; in the process that the garlic bulbs are radially enlarged, the current density of the blanks which continuously reach the annular restraining area is reduced, so that the temperature is reduced, the flowability of the garlic bulbs corresponding to the annular part of the annular restraining area is restrained, the trend that the garlic bulbs corresponding to the annular part of the annular restraining area drive the center of the garlic bulbs to axially flow is restrained, and the sinking trend of the center of the garlic bulbs is restrained finally. The invention solves the problem that the end surface concavity cannot be improved by changing the electric upsetting loading parameter, and improves the uniform refinement degree of garlic crystal grains while improving the end surface concavity.
Description
Technical Field
The present invention belongs to the field of metal plastic forming in material processing engineering.
Background
The electric upsetting process meets the requirement of local accurate material gathering of the super-large variable-cross-section long rod workpiece. The electric heating upsetting process couples three physical fields of electric heating force, current is conducted between the anvil electrode and the clamping electrode, heating is conducted through contact resistance and self resistance, certain upsetting force is applied to the right end of the blank, the blank at the cold end is sent into a heating area between the anvil electrode and the clamping electrode, and the blank is subjected to plastic deformation gradually to complete local material gathering. Since the plastic deformation region is strictly confined to the heating region, a product with a large deformation amount can be quickly realized.
When the super-large-specification gas valve member is formed by electric upsetting, the variable cross section of the large-specification gas valve is large, and the material is more during forming, and the range of electric upsetting forming technological parameters of the Nimonic 80A superalloy is narrow, so that the electric upsetting forming technology is extremely sensitive to temperature. The collapse of the bottom of the end face of the rod blank is deepened along with the increase of current density and upsetting force in the process of electric upsetting forming, and therefore a large pit is formed. In this patent, the distance from the anvil electrode where the lowest end surface collapses, i.e., the depth of the depression H, is used to indicate the size of the defect, as shown in fig. 1. On one hand, the end face depression can cause the current density at the concave part to be increased and the pressure of an anvil electrode to be difficult to accept, so that the temperature is too high and the dynamic recrystallization of crystal grains is reduced, and the phenomenon of uneven distribution of the crystal grains at the end face of the blank, namely the phenomenon of mixed crystals, is easily caused. On the other hand, the blank is not tightly attached to the upper die in the subsequent die forging process, so that incomplete attachment to a certain degree is achieved, and the risks of end face annular grooves and the problem of 'gas closure' are increased.
Disclosure of Invention
Aiming at the defects of the technology, the invention provides a large-specification electric upsetting method with gradient change of electrode resistivity, which solves the problem that the end surface depression cannot be improved by changing electric upsetting loading parameters.
In order to solve the technical problem, the invention provides a large-specification electric upsetting method with gradient change of electrode resistivity, which comprises the following steps of:
under the action of electric upsetting, the rod blank gradually and radially increases to form garlic bulbs;
when the garlic bulbs radially increase to the point that the garlic bulbs are separated from the anvil electrode in the center, the annular belt area of the anvil electrode, which is in contact with the garlic bulb edge at the moment, is used as an annular restraining area on the anvil electrode;
increasing resistivity on the annular keep-out region to locally reduce current density;
in the process that the garlic bulbs are radially enlarged, the current density of the blanks which continuously reach the annular restraining area is reduced, so that the temperature is reduced, the flowability of the garlic bulbs corresponding to the annular part of the annular restraining area is restrained, the trend that the garlic bulbs corresponding to the annular part of the annular restraining area drive the center of the garlic bulbs to axially flow is restrained, and the sinking trend of the center of the garlic bulbs is restrained finally.
Further, the surface layer of the anvil electrode is made by 3D printing, the annular suppression area is printed by a material with higher resistivity, and the rest area is printed by a material with lower resistivity. Or by coating the annular restraining zone on the anvil electrode with a resistive material.
Further, the annular restraining area is coated with a resistance material in the following manner: and respectively coating two different resistance materials on the inner ring and the outer ring of the annular inhibition area to form an inner ring coating and an outer ring coating, and enabling the resistivity of the outer ring coating to be larger than that of the inner ring coating.
Further, an additional coating layer is formed by coating a layer of resistance material with the resistivity smaller than that of the coating material of the inner ring outside the annular inhibition area.
The invention also provides an anvil electrode for improving the end face depression defect of the electric upsetting forming part, and a resistance material capable of increasing the resistivity is coated on the annular restraining area of the anvil electrode; the annular restraining zone is predetermined according to the forming characteristics of the rod blank in the electric upsetting forming process: when the garlic bulbs radially increase to the size that the garlic bulbs tend to sink axially at the center, the annular belt area of the garlic bulb edge contacting the anvil electrode at the moment is used as an annular restraining area on the anvil electrode.
Compared with the prior art, the invention has the advantages that:
1. in the process of electric upsetting, the outer blank obliquely flows to gather materials, the oblique flowing generates radial component force to enlarge the garlic, the reaction force of the axial component force causes the outer blank to generate axial flowing trend and can drive the central part of the rod blank to generate axial flowing trend, once the garlic is radially enlarged to a certain degree (determined according to the forming characteristic of the rod blank material), the central part of the rod blank has the tendency of end surface recession, if recession is not prevented in time, the recession is more and more serious, the recession range is larger and larger, and the axial recession depth of the recession is larger and larger; along with the increase of the dent, the center of the garlic bulb end surface gradually departs from the anvil electrode, the pressure of the anvil electrode is difficult to be received by the center of the garlic bulb end surface, the dynamic recrystallization is difficult to generate to refine the crystal grains at the center of the garlic bulb, and finally, the crystal grains at the center of the garlic bulb are thicker than those at the periphery. Meanwhile, the contact resistance is lacked in the center of the end face of the garlic, so that the temperature is too high, and the crystal grains are easy to coarsen. The invention dynamically prevents the end surface from sinking in the process of forming the electric upsetting piece, inhibits axial flow through the annular inhibition area, kills the sinking of the center of the garlic at the initial stage, and avoids the sinking from gradually expanding and deepening. The annular restraining region restrains the oblique flow of the corresponding outer billet, thereby restraining the reaction force of the axial component force and the axial flow of the corresponding outer billet to prevent the occurrence of the central depression.
2. The center of the garlic can be in close contact with the anvil electrode due to the inhibition of the sinking of the center of the garlic, and the center of the garlic can receive the pressure of the anvil electrode to generate dynamic recrystallization so as to refine the crystal grains in the center of the garlic; meanwhile, the contact resistance between the center of the garlic bulb and the anvil electrode also enables the current density and the temperature of the center of the garlic bulb to be reduced, crystal grains in the center of the garlic bulb are refined, and therefore the degree of uniformity and fineness of the crystal grains of the garlic bulb is improved.
3. The invention can make the center of the garlic always contact with the anvil electrode, so that the temperature of the center of the garlic is reduced, the temperature reduction of the center of the garlic can also inhibit the axial flow of the center of the garlic, and the sinking trend of the center of the garlic is inhibited again.
4. The inner ring and the outer ring of the annular inhibition area are respectively coated with two different resistance materials to form an inner ring coating and an outer ring coating, and the resistivity of the outer ring coating is larger than that of the inner ring coating, so that transition can be formed through the inner ring coating, and the influence on the hot formability caused by the too fast temperature drop of blanks reaching the outer ring coating is avoided.
5. After the blank reaches the additional coating, the current density is basically recovered to be consistent with the center of the garlic bulb, and the thermoforming property of the garlic bulb is ensured.
Drawings
FIG. 1 is a schematic illustration of the depth of subsidence;
FIG. 2 is a schematic view of an anvil electrode in this embodiment;
FIG. 3 is a schematic view of the electric upsetting principle in this embodiment;
FIG. 4 is an electric upsetting simulated forming shape of the comparative example at the time of electric upsetting 500 s;
FIG. 5 shows the electric upsetting simulated forming shape of the present embodiment at the time of electric upsetting for 500 s;
FIG. 6 is a simulated shape of electric upsetting of a comparative example at 900 s;
FIG. 7 shows the electric upsetting simulated shape of the present embodiment at the end of the electric upsetting;
FIG. 8 is an electric upsetting simulation formed shape of the comparative example at the end of electric upsetting;
fig. 9 is an electric upsetting simulation forming shape at the end of the electric upsetting of the present embodiment.
Detailed Description
Referring to fig. 2, 1 is an anvil cylinder, 2 is a secondary transformer, 3 is a chucking cylinder, 4 is a chucking electrode, 5 is a rod blank, 6 is an upsetting cylinder anvil, 7 is an annular band plating, and 8 is an anvil electrode.
A large-specification electric upsetting method for electrode resistivity gradient change comprises the following steps:
under the action of electric upsetting, the rod blank 5 gradually and radially increases to form garlic bulbs;
when the garlic bulbs radially increase to the extent that the garlic bulbs are separated from the anvil electrode at the center, the annular belt area of the anvil electrode in contact with the garlic bulb edge is used as an annular restraining area on the anvil electrode (when the annular belt area is not arranged);
increasing resistivity on the annular keep-out region to locally reduce current density;
in the process that the garlic bulbs are radially enlarged, the current density of the blanks which continuously reach the annular restraining area is reduced, so that the temperature is reduced, the flowability of the garlic bulbs corresponding to the annular part of the annular restraining area is restrained, the trend that the garlic bulbs corresponding to the annular part of the annular restraining area drive the center of the garlic bulbs to axially flow is restrained, and the sinking trend of the center of the garlic bulbs is restrained finally.
The annular restraining area on the anvil electrode is predetermined based on the forming characteristics of the rod blank during the forming process of the electric upsetting, and finite element modeling can be used to quickly determine the annular restraining area.
Determining the annular inhibition zone by adopting the following method:
performing electric upsetting simulation on a rod blank to be upset by adopting an anvil electrode with uniform resistivity, and taking an annular belt area of the anvil electrode in contact with the edge of the garlic as an inner annular area of an annular inhibition area on the anvil electrode when the garlic is radially increased to generate a separation trend between the garlic head and the anvil electrode; when the garlic bulb end surface is sunken to be stable, the annular belt area of the garlic bulb edge contacting with the anvil electrode at the moment is used as the outer annular area of the annular restraining area on the anvil electrode.
After the annular zone of inhibition is determined, the anvil electrode can be prepared in the following manner: 1) the surface layer of the anvil electrode is made by 3D printing, the annular inhibition area is printed by a material with higher resistivity, and the rest area is printed by a material with lower resistivity. 2) The resistivity is increased by coating the annular restraining area on the anvil electrode with a resistive material.
The finite element model used for the electric upsetting finite element simulation in the embodiment is as follows:
the Ni80A heat-resistant alloy rod blank used has a diameter of 85mm, a length of 3700mm and a total blank stroke of 3750 mm. Before electric upsetting forming, the blank is subjected to rounding treatment, and the radius is 22 mm.
The anvil electrode has high requirements on a series of physical properties such as wear resistance, oxidation resistance, resistivity (low) and the like, so that the TZM molybdenum-based high-temperature alloy is simulated. The anvil electrode coating region material has a higher resistivity than the anvil electrode.
In the present embodiment, the anvil electrode is prepared by using a coating resistance material, and referring to fig. 3, the inner ring and the outer ring of the annular suppression area are respectively coated with two different resistance materials to form an inner ring plating layer 701 and an outer ring plating layer 702, and the resistivity of the outer ring plating layer 701 is greater than that of the inner ring plating layer 701. An additional coating 703 is formed outside the annular confinement zone by coating a layer of resistive material having a resistivity less than the inner ring coating material.
The selection principle of coating materials is as follows:
firstly, the coating material of the annular belt follows the rule that the resistivity is increased from small to large to small from inside to outside, and meanwhile, the resistivity of the innermost layer material is higher than that of the outermost layer material.
Secondly, the annular belt is made of different coating materials, and the radial length occupied by each coating is determined according to the forming characteristics of the electric upsetting pieces with different specifications.
The inner ring coating is an indium tin oxide film coating, the outer ring coating is a zinc oxide based film, the additional coating is a Cu-Ni alloy coating, and the corresponding resistivities of the different coatings are shown in the following table.
TABLE 1 corresponding resistivities of different coatings
The rod blank of the comparative example was the same as the present embodiment, but the anvil electrode of the comparative example used a common anvil electrode of the prior art. According to the forming characteristics of the rod blank during the electric heading forming, the anvil electrode and the central portion of the rod blank were depressed when the rod blank was formed into the "garlic bulb" shape as in the comparative example, as shown in fig. 4, and therefore, the annular suppression area in the present embodiment could be determined. The inner ring plating layer and the outer ring plating layer cannot be too wide, otherwise the subsequent continuous heating deformation of the electric upsetting piece can be influenced, and the subsequent continuous heating deformation can be determined through simulation experiments according to the inhibition requirement.
At 500s, the electric heading simulated formed shapes of the comparative example and the present embodiment are shown in fig. 4 and 5. The electric upsetting simulation temperatures of the two types of anvils do not differ much. The simulation temperature of electric upsetting by using a common anvil is 1099 ℃, but the center of the rod blank has a sinking tendency. The electric upsetting simulation temperature of the anvil coated by brush coating is 1102 ℃, and the anvil electrode and the rod blank are still tightly attached at the time.
At 900s, the electrical upsetting simulated forming shapes of the comparative example and the present embodiment are shown in fig. 6 and 7. The electric upsetting simulation temperatures of the two types of anvils do not differ much. The electric upsetting simulation temperature of a common anvil is 1129 ℃, but the center of the rod blank sinks and the sinking depth is in a stable stage, and H is 7.8 mm; the simulated temperature of the electrical upsetting using the paint-coated anvil was 1128 c, at which the sinking of the bar blank also tended to be stable, reducing the sinking depth to 4.1mm and the sinking zone to a reduced extent compared to the conventional anvil type.
At the end of the upset, the uncoated and brushed anvil electrodes upset the mock formed shape as shown in fig. 8 and 9. The simulation temperature of the electric upsetting by adopting a common anvil is 1138 ℃, but the sinking depth of the center of the rod blank is 7.9mm at the moment; the electric upsetting simulation temperature with the paint-coated anvils was 1136 ℃, at which time the sinking depth of the bar blank was 4.2mm and the sinking area decreased.
The dimples in fig. 9 stayed in the areas corresponding to the annular suppression zones because Ni80A superalloy had strong heat sensitivity, but the center of the electric heading piece was almost free of dimples, and the shape of the dimples was greatly improved while the depth of the dimples was reduced.
According to the simulation comparison, the sinking depth and the sinking range of the large-size electric upsetting piece can be effectively reduced. The current density at the concave part is increased due to the concave end surface of the garlic, so that the temperature is too high, and the crystal grains are easy to coarsen; meanwhile, the concave part of the end surface of the garlic bulb is not in contact with the anvil electrode, so that the pressure of the anvil electrode is difficult to accept in the center of the garlic bulb, dynamic recrystallization is difficult to generate to refine crystal grains in the center of the garlic bulb, and finally the crystal grains in the center of the garlic bulb are thicker than those in the periphery. But because the invention improves the dent of the garlic bulb end surface, the degree of the even fineness of the garlic bulb crystal grains is improved.
Claims (10)
1. A large-specification electric upsetting method with gradient change of electrode resistivity is characterized by comprising the following steps:
under the action of electric upsetting, the rod blank gradually and radially increases to form garlic bulbs;
when the garlic bulbs radially increase to the point that the garlic bulbs are separated from the anvil electrode in the center, the annular belt area of the anvil electrode, which is in contact with the garlic bulb edge at the moment, is used as an annular restraining area on the anvil electrode;
increasing resistivity on the annular keep-out region to locally reduce current density;
in the process that the garlic bulbs are radially enlarged, the current density of the blanks which continuously reach the annular restraining area is reduced, so that the temperature is reduced, the flowability of the garlic bulbs corresponding to the annular part of the annular restraining area is restrained, the trend that the garlic bulbs corresponding to the annular part of the annular restraining area drive the center of the garlic bulbs to axially flow is restrained, and the sinking trend of the center of the garlic bulbs is restrained finally.
2. The large format electric upsetting method of electrode resistivity gradient as recited in claim 1 wherein the surface layer of the anvil electrode is 3D printed, the annular keep-out zone is printed with a higher resistivity material and the remaining area is printed with a lower resistivity material.
3. The large format electrical upset process of claim 1 wherein the resistivity is increased by coating the annular suppression zone on the anvil electrode with a resistive material.
4. The large format electrical upset process of claim 3 with electrode resistivity gradient, wherein the annular keep-out zone is coated with resistive material as follows: and respectively coating two different resistance materials on the inner ring and the outer ring of the annular inhibition area to form an inner ring coating and an outer ring coating, and enabling the resistivity of the outer ring coating to be larger than that of the inner ring coating.
5. The large format electrical upset method of claim 1 wherein the annular confinement zone is predetermined using simulation experiments; and (5) rounding the end surface of the rod blank before electric upsetting.
6. The large format electrical upset method of claim 4, wherein the annular exclusion zone is determined by:
performing electric upsetting simulation on a rod blank to be upset by adopting an anvil electrode with uniform resistivity, and taking an annular belt area of the anvil electrode in contact with the edge of the garlic as an inner annular area of an annular inhibition area on the anvil electrode when the garlic is radially increased to generate a separation trend between the garlic head and the anvil electrode; when the garlic bulb end surface is sunken to be stable, the annular belt area of the garlic bulb edge contacting with the anvil electrode at the moment is used as the outer annular area of the annular restraining area on the anvil electrode.
7. An anvil electrode, characterized in that an annular restraining area of the anvil electrode is coated with a resistive material capable of increasing resistivity; the annular suppression zone is determined by simulation in advance according to the forming characteristics of the rod blank in the electric upsetting forming process: performing electric upsetting simulation on a rod blank to be upset by adopting an anvil electrode with uniform resistivity, and taking an annular belt area of the anvil electrode in contact with the edge of the garlic as an inner annular area of an annular inhibition area on the anvil electrode when the garlic is radially increased to generate a separation trend between the garlic head and the anvil electrode; when the garlic bulb end surface is sunken to be stable, the annular belt area of the garlic bulb edge contacting with the anvil electrode at the moment is used as the outer annular area of the annular restraining area on the anvil electrode.
8. The anvil electrode according to claim 7, wherein the inner and outer rings of the annular restraining zone are coated with two different resistive materials to form an inner ring coating and an outer ring coating, respectively, and the outer ring coating has a resistivity greater than the resistivity of the inner ring coating.
9. The anvil electrode according to claim 8, wherein the inner ring coating is an indium tin oxide film coating and the outer ring coating is a zinc oxide based film.
10. The anvil electrode according to claim 8, wherein an additional coating is formed by coating an electrically resistive material having a resistivity less than the inner ring coating material outside the annular restraining region; the inner ring coating is an indium tin oxide film coating, the outer ring coating is a zinc oxide-based film, and the additional coating is a Cu-Ni alloy coating.
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Cited By (1)
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CN112828217A (en) * | 2020-11-18 | 2021-05-25 | 重庆电子工程职业学院 | Material increase regulation and control method for reducing sinking depth of electric upsetting end face to improve mixed crystals |
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