CN117531940A - Impact type runner external water bucket die forging manufacturing method and process structure - Google Patents
Impact type runner external water bucket die forging manufacturing method and process structure Download PDFInfo
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- CN117531940A CN117531940A CN202311543250.5A CN202311543250A CN117531940A CN 117531940 A CN117531940 A CN 117531940A CN 202311543250 A CN202311543250 A CN 202311543250A CN 117531940 A CN117531940 A CN 117531940A
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- external water
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 123
- 238000005242 forging Methods 0.000 title claims abstract description 107
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 73
- 238000000034 method Methods 0.000 claims abstract description 29
- 239000000463 material Substances 0.000 claims abstract description 17
- 238000013461 design Methods 0.000 claims abstract description 13
- 238000010586 diagram Methods 0.000 claims description 18
- 238000005266 casting Methods 0.000 claims description 12
- 239000000654 additive Substances 0.000 claims description 8
- 230000000996 additive effect Effects 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 8
- 238000005520 cutting process Methods 0.000 claims description 6
- 238000003754 machining Methods 0.000 claims description 6
- 238000010791 quenching Methods 0.000 claims description 5
- 230000000171 quenching effect Effects 0.000 claims description 5
- 238000005496 tempering Methods 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 4
- 238000001514 detection method Methods 0.000 claims description 3
- 238000009628 steelmaking Methods 0.000 claims description 3
- 238000012360 testing method Methods 0.000 claims description 2
- 238000000748 compression moulding Methods 0.000 description 3
- 238000005336 cracking Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 230000009977 dual effect Effects 0.000 description 3
- 238000005457 optimization Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
- B21J5/025—Closed die forging
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/24—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass dies
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
The invention discloses a die forging manufacturing method and a process structure of an external water bucket of an impact type rotating wheel, wherein the method comprises the steps of establishing an external water bucket model, symmetrically distributing two overflow surfaces of a target external water bucket to form a double water bucket model; closing the external gap between two opposite overflow surfaces of the double-water bucket model to form a double-water bucket semi-closed cavity model; designing and manufacturing an upper tire mold and a lower tire mold according to the double-bucket semi-closed cavity model; manufacturing a forging blank, and performing die forging by adopting a die forging machine and an upper die and a lower die to obtain a double-water-bucket product; after the product is detected to be qualified, the product is sawed into two single external water hoppers and is processed until the design dimensional accuracy requirement is met. The invention can improve the utilization rate of the material of the external water bucket of the impact type rotating wheel and reduce the manufacturing cost.
Description
Technical Field
The invention belongs to the technical field of production and manufacturing of impact type rotating wheels, and particularly relates to a die forging manufacturing method and a process structure of an external water bucket of an impact type rotating wheel.
Background
With the development of high-head high-capacity impact turbine units, the size of the core component runner of the impact turbine is larger and larger. The impact type rotating wheel mainly comprises a central body and a water bucket, and for the large-capacity impact type rotating wheel, a forge welding structure is generally adopted, namely, the water bucket with the root of the central body is processed by adopting a forge piece, and the external water bucket is manufactured by adopting welding. According to engineering needs, the manufacturing modes of the single external water bucket are various, including casting, forging and additive manufacturing, and the manufacturing quality and the manufacturing period of the external water bucket manufactured by adopting the forging have great advantages because the casting defects are not easy to control and the additive manufacturing period is too long.
However, because the external water bucket has a complex structure, the die forging is high in stress when adopting a conventional die forging mode, the material utilization rate is low, and the manufacturing cost is high. How to reduce the die forging difficulty of the external water bucket, improve the utilization rate of the material of the external water bucket of the impact type rotating wheel and reduce the manufacturing cost is a problem to be solved urgently.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a die forging manufacturing method and a process structure of an external water bucket of an impact type rotating wheel, wherein the rotating wheel is divided into a central body forging piece and an external water bucket through stress analysis, a model with a symmetrical overflow surface is built for the external water bucket, the model is subjected to closed treatment, a double-water bucket integrated semi-closed cavity is formed, the double water bucket is manufactured according to the semi-closed cavity, and the double water bucket is divided into two water buckets by adopting a sawing machine mode.
The aim of the invention is achieved by the following technical scheme:
a method of manufacturing an impact wheel external water bucket swage, said method comprising:
establishing an external water bucket model, and symmetrically distributing two overflow surfaces of a target external water bucket to form a double water bucket model;
closing the external gap between two opposite overflow surfaces of the double-water bucket model to form a double-water bucket semi-closed cavity model;
designing and manufacturing an upper tire mold and a lower tire mold according to the double-bucket semi-closed cavity model;
manufacturing a forging blank, and performing die forging by adopting a die forging machine and an upper die and a lower die to obtain a double-water-bucket product;
after the product is detected to be qualified, the product is divided into two pieces of single external water hoppers and is processed until the design dimensional accuracy requirement is met.
Further, the method further comprises:
before the steps of designing and manufacturing the upper and lower tire molds, simulating the forging process of the water bucket, and cutting and removing the area of the water bucket, in which the stress of the water diversion blade exceeds a preset threshold value;
after the product is divided into two single external water hoppers, a numerical control machine tool is adopted to carry out rough machining on the external water hoppers;
programming a robot additive manufacturing removal area according to the double-bucket semi-closed cavity model;
preheating and additive manufacturing the water diversion blade.
Further, the method for manufacturing the upper and lower tire molds specifically comprises the following steps:
designing a forging diagram according to the double-bucket semi-closed cavity model;
designing an upper tire mold and a lower tire mold according to the forging diagram, wherein a preset length is reserved on one side of the mold as machining allowance;
calculating the weight of the forging according to the design of the mould;
according to the weight of the forging and the forging process, designing the weight of a blank material of the forging;
and manufacturing an upper tire mold and a lower tire mold.
Further, the forging blank manufacturing specifically comprises:
VOD steelmaking is adopted to enable casting parameters to reach preset standards;
and forging the castings by adopting forging equipment after the castings are finished, so as to form forging blanks.
Further, the method further comprises:
and heating the forging blank to a preset temperature threshold before adopting a die forging machine and an upper die and a lower die to die forging, and performing quenching and tempering heat treatment after die forging is completed.
Further, the method further comprises:
after finishing the quenching and tempering heat treatment, cooling the forging, performing mechanical property test and flaw detection after cooling, and removing unqualified forging.
Further, the building of the external water bucket model includes:
according to the stress analysis of the rotating wheel, a region of the rotating wheel, of which the stress is lower than a preset threshold value, is found out, the rotating wheel is divided into a central body with a root water bucket and an external water bucket, and an external water bucket model is built according to the external water bucket.
In another aspect, the invention also provides an impact runner external water bucket die forging process structure, which is prepared according to any one of the methods.
The invention has the beneficial effects that:
(1) The invention adopts the forging to manufacture the external water bucket, ensures the quality and performance of the external water bucket of the impact type rotating wheel, adopts the die forging mode to manufacture the external water bucket, can improve the utilization rate of forging materials to more than 60 percent, and reduces the manufacturing cost.
(2) The invention adopts the double-bucket model for manufacturing, can reduce the design difficulty of the mould and better ensure the compression molding.
(3) According to the invention, the water diversion blade of the external water bucket model is removed, the model is simplified, the die forging cracking risk and die forging difficulty of the external water bucket are reduced, the manufacturing of the water diversion blade is completed by utilizing additive manufacturing, the utilization rate of forging materials can be improved to more than 70%, and is far higher than 12% of free forging, and the manufacturing cost is greatly reduced.
Drawings
FIG. 1 is a flow chart of a method for manufacturing an impact type runner external bucket die forging provided by an embodiment of the invention;
FIG. 2 is a block diagram of an impact wheel according to an embodiment of the present invention;
FIG. 3 is a block diagram of an impact wheel split according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a dual bucket model of an external bucket of an impact wheel according to an embodiment of the present invention;
FIG. 5 is a diagram of an impact runner dual bucket model according to an embodiment of the present invention;
FIG. 6 is a model diagram of an embodiment of the present invention after double-bucket closure optimization;
FIG. 7 is a schematic view showing the cutting of the water diversion blade according to the embodiment of the present invention;
FIG. 8 is a diagram of a double bucket structure after cutting by a water distribution blade according to an embodiment of the present invention.
Detailed Description
Other advantages and effects of the present invention will become apparent to those skilled in the art from the following disclosure, which describes the embodiments of the present invention with reference to specific examples. The invention may be practiced or carried out in other embodiments that depart from the specific details, and the details of the present description may be modified or varied from the spirit and scope of the present invention. It should be noted that the following embodiments and features in the embodiments may be combined with each other without conflict.
All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Because the external water bucket has a complex structure, the die forging is carried out by adopting a conventional die forging mode, the stress is larger, the material utilization rate is not high, and the manufacturing cost is higher. How to reduce the die forging difficulty of the external water bucket, improve the utilization rate of the material of the external water bucket of the impact type rotating wheel and reduce the manufacturing cost is a problem to be solved urgently.
In order to solve the technical problems, the following embodiments of the method and the process structure for manufacturing the external water bucket die forging of the impact type rotating wheel are provided.
Example 1
In order to solve the problems of low utilization rate of the external water bucket material and high manufacturing cost, the embodiment provides to find out the region with lower stress of the rotating wheel according to the stress analysis of the rotating wheel, and divide the rotating wheel into a center body forging and the external water bucket. And (3) establishing an external water bucket model, symmetrically distributing the two external water bucket overflow surfaces, and performing closed treatment on the model to form a double water bucket integrated semi-closed cavity. And designing and manufacturing an inner and outer tire mold, manufacturing a double water bucket by adopting a stamping mode after forging blank is finished, and dividing the double water bucket into two water buckets by adopting a sawing machine mode.
Referring to fig. 1, as shown in fig. 1, a flow chart of a method for manufacturing an impact type runner external water bucket die forging according to the present embodiment includes the following steps:
step one: and (3) establishing an external water bucket model, and symmetrically distributing two overflow surfaces of the target external water bucket to form a double water bucket model.
Specifically, referring to fig. 2 and 3, fig. 2 shows a structural diagram of an impact type runner of the present embodiment, fig. 3 shows a split structural diagram of the impact type runner of the present embodiment, and according to stress analysis, a low stress area is selected as a boundary line by combining with a center body forging manufacturing analysis, and the runner is divided into a center body with a root water bucket 1 and an external water bucket 2.
An external water bucket model is built according to the dividing line, and referring to fig. 4, a schematic diagram of a dual water bucket model of an external water bucket of an impact type runner according to the present embodiment is shown in fig. 4. The two external water hoppers are symmetrically distributed on the overflow surface, and referring to fig. 5, an impact type runner double water hopper model diagram of the embodiment is shown in fig. 5.
Step two: and closing the external notch between two opposite overflow surfaces of the double-water bucket model to form the double-water bucket semi-closed cavity model.
Referring to fig. 6, a model diagram of the double bucket closure optimization of the present embodiment is shown in fig. 6.
The integral die forging manufacturing is carried out by using the double-bucket integrated semi-closed cavity, so that on one hand, the design difficulty of a die can be reduced, and on the other hand, the die forging is carried out by using the semi-closed cavity, the compression molding can be improved, and the molding precision is improved.
Step three: and designing and manufacturing an upper tire mold and a lower tire mold according to the double-bucket semi-closed cavity model.
Specifically, the third step includes the following sub-steps:
step S11: and designing a forging diagram according to the double-bucket model structure.
Step S12: and designing an upper tire mold and a lower tire mold according to the forging diagram, wherein a certain machining allowance is reserved on one side of the mold.
Step S13: and calculating the weight of the forging according to the design of the mould.
Step S14: and designing the weight of forging blank materials according to the weight of the forging and the forging process.
Step S15: and manufacturing an upper tire mold and a lower tire mold.
Step four: and manufacturing a forging blank, and performing die forging by adopting a die forging machine and an upper die and a lower die to obtain a double-bucket product.
Specifically, the fourth step includes the following sub-steps:
step S16: and VOD steelmaking is adopted to control the quality of castings.
Step S17: and (5) carrying out preparation treatment after the casting is finished.
Step S18: forging the castings by adopting forging equipment to eliminate defects in the castings, improve the material performance and form forging blanks.
Step S19: and adopting a die forging machine and an upper die and a lower die to perform die forging, and die forging to obtain a double-bucket product.
As an implementation mode, the forging blank is heated to high temperature before die forging so as to ensure that the forging has enough ductility and prevent cracking in the stamping process.
After the die forging is completed, quenching and tempering heat treatment is performed.
Step five: after the product is detected to be qualified, the product is divided into two single external water hoppers and is processed until the design dimensional accuracy requirement is met.
Specifically, the fifth step comprises the following sub-steps:
step S20: in the embodiment, after the product is cooled, mechanical performance test and flaw detection are carried out, so that the quality and performance of the forging are ensured to meet the requirements, and the product with unqualified quality is removed.
Step S21: and after the inspection is qualified, sawing the double water bucket into two single external water buckets by adopting a sawing machine.
Step S22: and processing the external water bucket by adopting a numerical control machine tool until the design dimensional accuracy requirement is met.
The embodiment adopts the forging to manufacture the external water bucket, ensures the quality and performance of the external water bucket of the impact type rotating wheel, adopts a stamping die forging mode to manufacture the external water bucket, can improve the utilization rate of forging materials to more than 60 percent, is far higher than 12 percent of free forging, and greatly reduces the manufacturing cost. The embodiment adopts the double-bucket model for manufacturing, can reduce the design difficulty of the mould, and simultaneously better ensures compression molding.
Example 2
In order to further improve the utilization rate of forging materials, the embodiment performs secondary design on the double-bucket integrated semi-closed cavity of the embodiment, and the machining area is divided into a die forging area and an material adding area.
Specifically, compared with embodiment 1, the method for manufacturing the impact type runner external water bucket die forging provided by the embodiment further comprises the following steps:
before the steps of designing and manufacturing the upper and lower tire molds, simulating the forging process of the water bucket, and cutting and removing the area where the stress of the water diversion blade of the water bucket exceeds a preset threshold value.
Referring to fig. 7, a water diversion blade cutting schematic diagram of the present embodiment is shown in fig. 7, and the hatched portion indicates the region where the stress of the water diversion blade of the water bucket is greater. Referring to fig. 8, fig. 8 shows a structure of a double bucket after the water diversion blade of the present embodiment is cut.
After the product is divided into two single external water hoppers, a numerical control machine is used to roughen the external water hoppers.
And programming a robot additive manufacturing removal area according to the double-bucket semi-closed cavity model.
And preheating and adding materials to manufacture a water diversion blade, and finally finishing the external water bucket through a numerical control machine tool after heat treatment until the design dimensional accuracy requirement is met.
The other manufacturing process was the same as the steps in example 1.
According to the embodiment, through simplifying a model, the die forging cracking risk and die forging difficulty of the external water bucket are reduced, the utilization rate of forging materials can be improved to be more than 70%, the utilization rate is far higher than that of free forging and is 12%, and the manufacturing cost is greatly reduced.
The foregoing description of the preferred embodiments of the invention is not intended to be limiting, but rather is intended to cover all modifications, equivalents, and alternatives falling within the spirit and principles of the invention.
Claims (8)
1. A method of manufacturing an impact wheel external water bucket swage, said method comprising:
establishing an external water bucket model, and symmetrically distributing two overflow surfaces of a target external water bucket to form a double water bucket model;
closing the external gap between two opposite overflow surfaces of the double-water bucket model to form a double-water bucket semi-closed cavity model;
designing and manufacturing an upper tire mold and a lower tire mold according to the double-bucket semi-closed cavity model;
manufacturing a forging blank, and performing die forging by adopting a die forging machine and an upper die and a lower die to obtain a double-water-bucket product;
after the product is detected to be qualified, the product is divided into two pieces of single external water hoppers and is processed until the design dimensional accuracy requirement is met.
2. The method of manufacturing an impact wheel outer water bucket swage of claim 1, further comprising:
before the steps of designing and manufacturing the upper and lower tire molds, simulating the forging process of the water bucket, and cutting and removing the area of the water bucket, in which the stress of the water diversion blade exceeds a preset threshold value;
after the product is divided into two single external water hoppers, a numerical control machine tool is adopted to carry out rough machining on the external water hoppers;
programming a robot additive manufacturing removal area according to the double-bucket semi-closed cavity model;
preheating and additive manufacturing the water diversion blade.
3. The method for manufacturing the external water bucket die forging of the impact type rotating wheel according to claim 1, wherein the steps of manufacturing the upper die and the lower die specifically comprise the following steps:
designing a forging diagram according to the double-bucket semi-closed cavity model;
designing an upper tire mold and a lower tire mold according to the forging diagram, wherein a preset length is reserved on one side of the mold as machining allowance;
calculating the weight of the forging according to the design of the mould;
according to the weight of the forging and the forging process, designing the weight of a blank material of the forging;
and manufacturing an upper tire mold and a lower tire mold.
4. The method for manufacturing the external water bucket die forging of the impact type rotating wheel according to claim 1, wherein the step of manufacturing the forging blank specifically comprises the following steps:
VOD steelmaking is adopted to enable casting parameters to reach preset standards;
and forging the castings by adopting forging equipment after the castings are finished, so as to form forging blanks.
5. The method of manufacturing an impact wheel outer water bucket swage of claim 1, further comprising:
and heating the forging blank to a preset temperature threshold before adopting a die forging machine and an upper die and a lower die to die forging, and performing quenching and tempering heat treatment after die forging is completed.
6. The method of manufacturing an impact wheel outer water bucket swage of claim 5, further comprising:
after finishing the quenching and tempering heat treatment, cooling the forging, performing mechanical property test and flaw detection after cooling, and removing unqualified forging.
7. The method of manufacturing an impact wheel outer water bucket swage of claim 1, wherein said building an outer water bucket model comprises:
according to the stress analysis of the rotating wheel, a region of the rotating wheel, of which the stress is lower than a preset threshold value, is found out, the rotating wheel is divided into a central body with a root water bucket and an external water bucket, and an external water bucket model is built according to the external water bucket.
8. A process structure for swaging an external bucket of an impact wheel, said process structure being prepared according to the method of any of claims 1-7.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311543250.5A CN117531940A (en) | 2023-11-17 | 2023-11-17 | Impact type runner external water bucket die forging manufacturing method and process structure |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311543250.5A CN117531940A (en) | 2023-11-17 | 2023-11-17 | Impact type runner external water bucket die forging manufacturing method and process structure |
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| Publication Number | Publication Date |
|---|---|
| CN117531940A true CN117531940A (en) | 2024-02-09 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311543250.5A Pending CN117531940A (en) | 2023-11-17 | 2023-11-17 | Impact type runner external water bucket die forging manufacturing method and process structure |
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| Country | Link |
|---|---|
| CN (1) | CN117531940A (en) |
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2023
- 2023-11-17 CN CN202311543250.5A patent/CN117531940A/en active Pending
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