US20050086783A1 - Precision-forging parts manufacturingprocess - Google Patents

Precision-forging parts manufacturingprocess Download PDF

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Publication number
US20050086783A1
US20050086783A1 US10/878,042 US87804204A US2005086783A1 US 20050086783 A1 US20050086783 A1 US 20050086783A1 US 87804204 A US87804204 A US 87804204A US 2005086783 A1 US2005086783 A1 US 2005086783A1
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US
United States
Prior art keywords
forging
parts
tooling equipment
points
digital model
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/878,042
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English (en)
Inventor
Dominique Beignon
Camille Cougnaud
Marc Lepetit
Bertrand Bouillot
Lionel Valery
Jean-Claude Plazanet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Aircraft Engines SAS
Original Assignee
SNECMA Moteurs SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SNECMA Moteurs SA filed Critical SNECMA Moteurs SA
Publication of US20050086783A1 publication Critical patent/US20050086783A1/en
Assigned to SNECMA MOTEURS reassignment SNECMA MOTEURS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEIGNON, DOMINIQUE, BOUILLOT, BERTRAND, COUGNAUD, CAMILLE, LEPETIT, MARC, PLAZANET, JEAN-CLAUDE, VALERY, LIONEL
Assigned to SNECMA reassignment SNECMA CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: SNECMA MOTEURS
Abandoned legal-status Critical Current

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Classifications

    • 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
    • B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
    • 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
    • B21K3/00—Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like
    • B21K3/04—Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like blades, e.g. for turbines; Upsetting of blade roots
    • 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
    • B21K5/00—Making tools or tool parts, e.g. pliers
    • B21K5/20—Making working faces of dies, either recessed or outstanding
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49764—Method of mechanical manufacture with testing or indicating
    • Y10T29/49769—Using optical instrument [excludes mere human eyeballing]

Definitions

  • the present invention concerns the field of precision forging of metal parts and in particular of complex and awkward-shaped parts, such as large-sized blades for turbo machines.
  • forging techniques are preferably implemented when they should absorb significant loads during operation. Such is the case for compressor blades or turbo-jet engine blowers for which the internal loads are generated notably by the vibrations and the centrifugal forces to which they are subjected.
  • Forging consists in deforming plastically a block of metal by imparting shocks or applying a pressure.
  • the process is generally composed of several steps, while forming successive blanks, which come gradually closer to the finished part. If required, the forging of the part is completed by a calibration phase leading to more accurate shapes.
  • an operating mode comprises the steps of upsetting, extrusion and stamping, out of bars.
  • the metal bars are prepared by undergoing an enamelling operation. It is a glass-based coating whose purpose is to facilitate the flow of matter into the tooling equipment. It also serves as thermal insulation while maintaining the temperature during the transfer from the oven to the press and while preventing any thermal shocks when the part contacts the tooling equipment. Its function also consists in protecting the part against oxidation. According to a preferred embodiment, the coating is sprayed electrostatically on the parts before loading into the oven.
  • both shells or upsetting tools are lubricated.
  • the upsetting phase consists in pushing the end of the bar, raised to a temperature ensuring good ductility, by means of a punch towards the inside of the cavity formed by both shells.
  • the upsetting is performed in several successive steps in suitable tools. For example, this process may be appropriate to form the feet of compressor blades as well as, if needed, the fins.
  • the enamel coating which has warped, as well as the scale generated, must be eliminated using appropriate baths, before building a new coat of enamel.
  • the upsetting is preceded by an extrusion step.
  • step consists in stretching the metal slug through a die whereof the profile corresponds to that to be realised.
  • This mechanical forging operation consists in elaborating a part by forcing a blank thereof to fill in, by imparting shocks or by applying pressure, a print engraved in a stamping die corresponding to the shape of the part to be obtained.
  • a stamping die corresponding to the shape of the part to be obtained.
  • the forging is performed in hot condition up to a certain limit imposed by the structural evolution of the material which alters the mechanical properties thereof.
  • a known shaping operation includes two stamping operations:
  • the stamping operations are carried out on hydraulic or screw-type presses whereof the stamping dice are pre-heated.
  • the forging time is relatively short to avoid too rapid cooling down of the part and excessive heating of the stamping die by thermal conduction between the part and said stamping die inasmuch as the temperature of the tooling equipment differs from that of the part.
  • a lubricant is applied to the engraving of the stamping die to slow down the cooling process of the part, for easier flow of matter and to reduce the forging loads.
  • the part is machined and polished to final sizes. Such operation is made necessary by reason of the excessive thickness remaining after forging. In fact, the engraving of the stamping die is determined in order to keep the excessive thickness of the part. After forging, machining and polishing enable to give the finished part the precise shape and the surface condition requested.
  • polishing is an important operation. Its purpose is to eliminate the defects resulting from the forging operation and which are liable to give rise to developing cracks.
  • the present invention relates first of all to the development of tooling equipment which are the stamping dice and the shells introduced above. There is a need, indeed, to improve these operations which have a negative contribution to the global economy of this technique.
  • the print of the stamping die has not rigorously the shape and the sizes of the raw forging part to be obtained. It departs therefrom by “corrective terms” which compensate for elastic-plastic deformations of the tooling equipment during the forging cycle. We do not know exactly how to forecast such corrective terms and it is therefore necessary to retouch the stamping die further to the measurements taken on the test pieces obtained.
  • precision forging, excessive thicknesses are small, for example 0.8 mm, so that the finished part may be obtained by polishing the raw part using a grinding belt or, if needed, notably if the part is made of titanium, by the combination of chemical machining and grinding belt polishing. Such is the case for the airfoil part of blades.
  • stamping die can be put into service in order to manufacture series parts.
  • the stamping die degrades gradually in operation, and it becomes necessary, for example after 1000 to 5,000 parts as the case may be, to rehabilitate the stamping die or to use another.
  • the rehabilitation of a degraded stamping die consists, according to a first method, in reloading the zones wherefrom matter has been torn off and in machining and polishing a new print.
  • a second method the print is reconstructed completely by machining, after having eliminated the nitrided layer and removed a thickness of several millimetres of matter. This technique is designated as rewashing.
  • the rehabilitation of a stamping die or the manufacture of a new stamping die require the same adjustments as the initial stamping die. They are consequently also long and costly.
  • abrasive belt finishing removes, at each pass, a pre-established thickness of matter, said thickness increasing with the speed of the abrasive belt and the pressure exerted by the belt on the part, said thickness decreasing with the forward speed of the belt with respect to the part.
  • the shape and the sizes of the part after an abrasive belt pass depend therefore directly on the shape and the sizes of the part before said pass.
  • Parts are sampled for regular checking purposes.
  • the tooling equipment is rehabilitated or new tooling equipment is manufacture.
  • the parts obtained with the new stamping dice or the rehabilitated stamping dice may require several finishing passes, separated by measurements, so that they are rigorously identical to the parts obtained with the first stamping die. This similarity in results is particularly important in the case of blade sets on a turbo-jet engine rotor stage.
  • the problem to be solved is to reduce the finishing cost and to obtain rigorously identical parts although they may have been forged with different stamping dice. It also consists in avoiding wasting parts because they do not meet the specifications, which in the case of precision forging is an important criterion for validation of the process.
  • this problem can be solved with a precision-forging parts manufacturing process including
  • the parts are subjected to a finishing treatment directly after forging, said treatment including mechanic polishing.
  • the finishing treatment comprises a combination of mechanical polishing and of chemical machining.
  • Chemical machining consists of chemical dissolution of the titanium alloys. Matter removal is conditioned by the soak time of the parts.
  • the method according to the invention is remarkable in that:
  • polishing is automated thanks to abrasive belts.
  • a machine exhibiting a contact wheel system driving an abrasive belt is used. This type of machine advantageously enables controlling the removal value and the surface condition requested, on the basis of simple machine parameters such as the load exerted by the contact wheel on the part, the running speed of the belt on the contact wheel as well as the relative displacement velocity of the wheel with respect to the part to be processed.
  • This process enables to master the excessive thickness removed and to reduce considerably the number of successive finishing stapes after forging.
  • the geometry of the part as well as its finishing surface condition are ensured, with a minimum of manual retouching operations, let alone, no such retouching operation at all.
  • FIG. 1 represents a stamping die
  • FIG. 2 an upsetting shell
  • FIG. 3 a belt polishing machine.
  • the tooling equipment involved in the forging method of the invention is complex in shaped with, additionally:
  • the stamping die degrades gradually by wearing the print, notably, and by plastic deformation.
  • said equipment is rehabilitated or new tooling equipment is manufactured on the basis of information saved on the tooling equipment adjusted previously. Continuity of the method is thereby ensured.
  • MMT three-dimensional measuring machines
  • the contact free sensors the most current ones are those based on optical techniques with one or several laser sources or laser free optical techniques. Both use the measuring principle based on trigonometry and more particularly on triangulation.
  • the part is illuminated by a coherent light source, a laser beam generally, and one or several CCD (charged coupled device) type cameras observe the scene from an angle which is different generally from that of the emission.
  • CCD charged coupled device
  • the principle is based upon the projection, onto the part, of a regular grid, a fringe network, then the calculation of the superficial points of the object by triangulation.
  • the geometry of the surface follows a reconstruction stage. Such operation may be carried out by data-processing means known to the man of the art.
  • the cloud of points obtained by digitalisation is collected. According to the quality of this cloud of points, it may be necessary to apply a filter thereto whereof the purpose is to attenuate the multiple small local variations, while eliminating aberrant points, measuring errors, etc.
  • the digital model When the digital model is performed, it is saved under a CAD file format to be importer into the CAM environment in order to generate the manufacturing strategy, then a digital programme on a machining tool, for example a UHS high-speed type machining tool.
  • a machining tool for example a UHS high-speed type machining tool.
  • This programme is then used for the manufacture of new tooling equipment, stamping dice, so that they are rigorously identical to the perfect initial tooling equipment.
  • the geometry of the part is controlled by a multidimensional-type technique and the thicknesses and the geometrical shapes are re-balanced over the whole blade by combination of weak point masking using an adhesive tape and chemical machining.
  • the machine comprises a frame 1 with a parts support 2 , a compressor blade for example, which is held horizontal along its main axis, by means of a mechanic or hydraulic flanging device.
  • a first engine 4 ensure rotational position (rotational axis U) of the part around its main axis.
  • a second engine 6 ensures displacement of the support of the part along a translation axis (x).
  • a third engine 8 drives the abrasive belt mounted on a contact wheel 10 and stretched by a system of rollers.
  • the rotational axis of the wheel 10 is moreover positioned in translation along both axes (y and z) perpendicular to the first axis x and in rotation along both their associated rotational axes V and W.
  • the contact surface of the wheel is held constantly in tangential position in relation to the surface of the part.
  • a wheel of 25 mm in width with 120 mm in external diameter is used.
  • grooves have been provided on sufficiently rigid coating; for its Shore hardness is 65.
  • the polishing operation consists in moving the part along the axis x and rotating said part around its axis.
  • the wheel is held constantly in tangential contact with the surface of the part.
  • the wheel is subjected to a pressure determined by the pressure exerted by a cylinder, a belt velocity determined in order to remove a controlled quantity of matter taking into account the infeed of the part with respect to the wheel.
  • the polishing machine Once the part has exited the polishing machine, it is ready for machining the foot and, if needed, the fin with a blade which meets the geometrical as well as the surface condition requirements.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
US10/878,042 2003-07-23 2004-06-29 Precision-forging parts manufacturingprocess Abandoned US20050086783A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0309000 2003-07-23
FR0309000A FR2857889B1 (fr) 2003-07-23 2003-07-23 Procede de fabrication de pieces par forgeage de precision

Publications (1)

Publication Number Publication Date
US20050086783A1 true US20050086783A1 (en) 2005-04-28

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ID=33484693

Family Applications (1)

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US10/878,042 Abandoned US20050086783A1 (en) 2003-07-23 2004-06-29 Precision-forging parts manufacturingprocess

Country Status (10)

Country Link
US (1) US20050086783A1 (fr)
EP (1) EP1500444B1 (fr)
JP (1) JP2005040863A (fr)
CN (1) CN100488662C (fr)
DE (1) DE602004001816T2 (fr)
FR (1) FR2857889B1 (fr)
IL (1) IL162826A (fr)
MX (1) MXPA04007142A (fr)
RU (1) RU2355503C2 (fr)
ZA (1) ZA200405193B (fr)

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CN101559574B (zh) * 2008-04-18 2011-03-23 北京胜为弘技数控装备有限公司 六轴联动数控砂带磨床及加工汽轮机叶片的方法
CN102837246A (zh) * 2012-09-14 2012-12-26 西安航空动力股份有限公司 航空发动机精锻叶片进、排气边缘柔性磨削方法
CN103028693A (zh) * 2011-09-29 2013-04-10 沈阳黎明航空发动机(集团)有限责任公司 一种精锻叶片预成型方法
CN103042145A (zh) * 2012-12-25 2013-04-17 国营第六一六厂 扳手精密模锻成形工艺
CN113205532A (zh) * 2021-05-06 2021-08-03 湖南协优易机械工业有限公司 一种锻压设备控制装置
US11673211B2 (en) 2018-01-12 2023-06-13 General Electric Company Temperature control system for additive manufacturing and method for same

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FR2947197B1 (fr) * 2009-06-26 2011-07-15 Snecma Procede de fabrication d'une piece forgee avec polissage adaptatif
CN101791671B (zh) * 2009-12-22 2011-08-17 沈阳黎明航空发动机(集团)有限责任公司 一种钛合金叶片精密成形锻造方法
CN101811169B (zh) * 2010-04-09 2012-03-21 无锡透平叶片有限公司 一种叶片模具的分型自锁结构及分型设计方法
CN102162469B (zh) * 2011-04-14 2013-07-03 四川振强模锻有限公司 一种风机铝合金叶片及其制造工艺
JP5802972B2 (ja) * 2011-07-11 2015-11-04 大同特殊鋼株式会社 タービンブレードの製造方法
FR2979267B1 (fr) * 2011-08-26 2014-04-18 Snecma Procede de fabrication d'une piece par forgeage
CN102974736A (zh) * 2012-11-30 2013-03-20 无锡透平叶片有限公司 透平叶片坯料的定位结构
CN103878292A (zh) * 2012-12-21 2014-06-25 陕西宏远航空锻造有限责任公司 一种Cr-Ni-Mo系不锈钢叶片的锻造方法
CN103357806B (zh) * 2013-07-22 2015-07-08 上海驳原金属材料有限公司 超细晶粒钛合金tc4叶片的制造工艺
CN103691866B (zh) * 2013-12-15 2015-10-14 无锡透平叶片有限公司 一种提高叶片坯料在模具上定位稳定性的方法
FR3049883B1 (fr) * 2016-04-12 2018-05-04 Safran Noyau de conformation a chaud d'une piece metallique et procede de fabrication
JP7253995B2 (ja) * 2019-07-24 2023-04-07 株式会社日立製作所 製造工程設計方法及び製造工程設計システム
CN112756921B (zh) * 2021-01-08 2022-03-25 台州市黄岩炜大塑料机械有限公司 塑料扩口管件模具扩口滑块加工方法
CN114074170B (zh) * 2021-11-19 2024-05-10 中国航发贵州黎阳航空动力有限公司 一种航空发动机叶片精锻件终锻模的优化设计方法
CN114453543B (zh) * 2022-01-27 2023-04-04 景德镇明兴航空锻压有限公司 一种tc4钛合金棒材的锻造设备及锻造方法

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EP1500444B1 (fr) 2006-08-09
FR2857889B1 (fr) 2005-09-23
FR2857889A1 (fr) 2005-01-28
EP1500444A1 (fr) 2005-01-26
ZA200405193B (en) 2005-05-25
IL162826A (en) 2008-07-08
DE602004001816D1 (de) 2006-09-21
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DE602004001816T2 (de) 2007-03-29
CN1583315A (zh) 2005-02-23

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