WO2019214055A1 - 超声辅助精锻方法与装置 - Google Patents

超声辅助精锻方法与装置 Download PDF

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Publication number
WO2019214055A1
WO2019214055A1 PCT/CN2018/095532 CN2018095532W WO2019214055A1 WO 2019214055 A1 WO2019214055 A1 WO 2019214055A1 CN 2018095532 W CN2018095532 W CN 2018095532W WO 2019214055 A1 WO2019214055 A1 WO 2019214055A1
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Prior art keywords
ultrasonic
punch
vibration
ultrasonic vibration
die
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PCT/CN2018/095532
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English (en)
French (fr)
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姜银方
沙德利
朱梦成
姜文帆
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江苏大学
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Publication of WO2019214055A1 publication Critical patent/WO2019214055A1/zh

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    • 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
    • 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

Definitions

  • the invention relates to the field of precision forging, in particular to a method and a device for ultrasonic vibration assisted precision forging.
  • the forging industry has always been an important foundation for industries such as automobiles, mining, energy, construction, aerospace, and weapons.
  • Second World War With the development of modern large-scale production, a variety of new technologies with no cutting were born.
  • the forging process has broken through the scope of rough production. People can produce a lot of forged parts close to the finished product, with good surface quality, less machining allowance and high dimensional accuracy.
  • Precision forging improves the material utilization rate, partially eliminates or reduces the cutting process, and continuously distributes the metal fibers along the product profile, which increases the bearing capacity of the parts and improves the overall performance.
  • the existing precision forging production technologies mainly include several methods such as hot forging, warm forging and cold forging.
  • the processes of forging and extrusion in the plastic forming method have disadvantages such as excessive deformation force, inaccurate contour of the workpiece, poor metal filling property, low mold life and difficulty in demoulding after forming.
  • gear precision forging the spiral tooth structure of the spiral bevel gear is special, and the curved tooth surface can not be formed by one step precision forging, and the spiral bevel gear hot precision forging and cold fine shaping composite process (patent publication number CN102441773A) adopts heat.
  • Precision forging forming, isothermal spheroidizing annealing, sand blasting, deflashing and cold finishing process manufacturing improve material utilization and improve product quality, but the process is numerous, there is incomplete filling phenomenon in the forging process, there is forged product
  • the problem of the mold is relatively difficult, and the local stress of the tooth-shaped finishing mold in the cold-finishing stage is relatively large, so that the life of the mold is lowered.
  • Spiral bevel gear precision forging forming manufacturing method (patent publication number CN102240774A) is to heat the material section to 1150-1180 ° C, and then thick, punching, expanding, pre-forging, final forging, spheroidizing annealing, surface blasting Cleaning, surface phosphating and saponification, and finally finishing the tooth profile at room temperature; the process has many processes, the processing cost is high, and there is a phenomenon that the forging stress is too large to cause internal fracture of the workpiece, which is redundant at the normal temperature finishing stage.
  • the lateral flow of the metal easily breaks the arc tooth profile on the mold or breaks the arc teeth of the product, resulting in a very short die life.
  • the gear temperature precision forging process method (Patent Publication No. CN1799726A) heats the steel billet between hot forging and cold forging. Under this temperature condition, the surface of the steel billet does not decarburize except for a small amount of oxidation. The process is small, the overall manufacturing cost is low, but the accuracy, quality, mechanical strength, and the service life of the forging die are also between the hot precision forging and the cold precision forging process.
  • Gear hot-forging processing technology of carburized steel 20CrMnTi (patent publication number CN102764838A) adopts piercing length, blanking, forging die, deburring, forging treatment (including quenching, quenching and tempering heat treatment, tooth surface heat treatment) Through nitriding, surface quenching, normalizing, sandblasting to remove scale, surface acid treatment), tooth-shaped cold finishing forging process, the process simplifies the gear forging process, reduces the production process, and improves the use of the mold Life, but there are problems of excessive deformation force, inaccurate forming profile and difficulty in demoulding after forming.
  • Zhuang Xincun and others of Shanghai Jiaotong University passed the ultrasonic assisted 1050 aluminum alloy compression test and found that the degree of forming force reduction is proportional to the ultrasonic amplitude, and the friction between the workpiece and the mold is reduced, which improves the surface quality of the workpiece.
  • Zhang Yang designed a device for extrusion-casting aluminum alloy by ultrasonic-pressure coupling. It was found that ultrasonic vibration and pressure coupling can reduce the grain size, increase the proportion of equiaxed crystal structure, and the degree of refinement of each sampling position is relatively uniform. Bunget et al.
  • the invention can reduce the contact friction coefficient between the blank and the mold by adding ultrasonic vibration during the precision forging process; refining the micro-grain structure of the metal fiber, so that the grain refinement degree of each position of the workpiece is relatively uniform; It can alleviate or eliminate the stress concentration phenomenon in the severe deformation zone of the tool, make the stress distribution more uniform, reduce the roughness of the forming surface of the workpiece, and reduce or avoid the defects such as cracks, cracks and scratches in the forging process.
  • the present invention adds ultrasonic vibration to the auxiliary forming process during the precision forging process, so that the blank is in the ultrasonic vibration during the extrusion precision forging process, which greatly reduces the deformation resistance of the metal, and reduces or avoids the appearance of the workpiece during the precision forging process.
  • Cracks, cracks, scratches and other defects reduce the contact friction coefficient between the blank and the mold, improve the filling of the metal, make the forming profile of the part more precise; ultrasonic vibration and pressure coupling can reduce the grain size and refine the metal
  • the microscopic grain structure of the fiber reduces the roughness of the formed surface of the part.
  • Ultrasonic-assisted precision forging method ultrasonic vibration mechanism is arranged on the conventional precision forging die, so that the upper ultrasonic vibration mechanism is fixedly connected to the upper punch through the upper punching sleeve and the middle slot of the upper template, and the upper ultrasonic transducer is electrically connected.
  • the signal is converted into mechanical vibration and transmitted to the upper ultrasonic horn.
  • the upper ultrasonic horn transmits the amplified ultrasonic vibration to the upper punch, and the upper punch transmits the vibration to the blank, so that the upper punch generating the resonance will be ultrasonic.
  • the vibration is transmitted to the blank, and the lower ultrasonic vibration mechanism is the same as the upper ultrasonic vibration mechanism.
  • the lower ultrasonic vibration mechanism is fixedly connected to the upper punch through the undercut cushion sleeve and the middle slot of the lower template, and the lower ultrasonic transducer will be The electrical signal is converted into mechanical vibration and transmitted to the lower ultrasonic horn.
  • the lower ultrasonic horn transmits the amplified ultrasonic vibration to the lower punch, and the lower punch transmits the vibration to the blank, so that the lower punch that generates resonance will Ultrasonic vibration is transmitted to the blank;
  • Step S1 Firstly, according to the material, shape complexity, size and forming temperature of the forging, the ultrasonic vibration frequency is selected, the ultrasonic vibration power is adjusted, that is, the ultrasonic vibration amplitude is adjusted, and the transducer or the horn is replaced to generate a suitable ultrasonic vibration mode.
  • simulation calculation and design of the length of the punch is Wavelength, the natural frequency of the punch is the ultrasonic vibration frequency;
  • Step S2 fixedly connecting the upper ultrasonic vibration mechanism and the lower ultrasonic vibration mechanism to the upper punch and the lower punch respectively, and mounting the same on the precision forging die, so that the upper punch and the lower punch pass through the upper die and the lower punch.
  • the through groove formed in the concave mold puts the previously processed blank into the mold, the press works, and the ultrasonic vibration mechanism descends to start clamping;
  • Step S3 After the upper concave die and the lower concave die are closed, the clamping cylinder is locked, and the upper ultrasonic vibration mechanism and the lower ultrasonic vibration mechanism connected with the upper punch and the lower punch are simultaneously opened, and the upper punch is further pressed down, and the lower punch is further pressed. The head is further pressed, the formed part is pressed, and the pressure is maintained;
  • Step S4 The ultrasonic vibration on the upper punch and the lower punch is closed, and the upper concave mold portion is ascended. After the mold is opened, the ultrasonic vibration mechanism on the side of the lower punch is opened, and the forging member is ejected through the lower punch.
  • the frequency of the ultrasonic generator during the ultrasonic assisted precision forging ranges from 15 kHz to 80 kHz; the amplitude of the ultrasonic wave ranges from 5 ⁇ m to 80 ⁇ m; the vibration modes used by the ultrasonic wave during the precision forging process are radial vibration, longitudinal vibration, bending vibration, and longitudinal torsion. Vibration, longitudinal bending vibration or bending and torsional vibration.
  • the ultrasonic vibration frequency set on the lower punch is 15KHz-50KHz; the ultrasonic amplitude range is 5 ⁇ m-50 ⁇ m; the ultrasonic vibration mode is longitudinal vibration, bending vibration, longitudinal Torsional vibration, longitudinal bending vibration or bending and torsional vibration.
  • ⁇ is the propagation wavelength of the ultrasonic wave in the punch material
  • c is the propagation sound velocity of the ultrasonic wave in the punch material
  • f is the ultrasonic frequency
  • ultrasonic vibration may be applied to one end surface of the forging in the forging process, ultrasonic vibration may be simultaneously applied to both end faces, and ultrasonic vibration may be applied to the local region; the upper ultrasonic horn and the upper punch and the lower The ultrasonic horn and the lower punch transmit the ultrasonic vibration using a stud connection or a direct contact.
  • the device for ultrasonic assisted precision forging comprises an upper concave die, a lower concave die, an upper punch, a lower punch, an upper ultrasonic vibration mechanism and a lower ultrasonic vibration mechanism, and the upper concave die, the lower concave die and the upper part when the mold is closed
  • the punch and the lower punch together form a closed cavity
  • the upper ultrasonic vibration mechanism and the lower ultrasonic vibration mechanism have the same structure and are symmetrically distributed vertically
  • the upper ultrasonic vibration mechanism includes an upper ultrasonic flange fixing plate, an upper ultrasonic pressure plate, An upper ultrasonic horn, an upper ultrasonic transducer, an upper ultrasonic fixed plate and a pull-up rod
  • the upper end of the upper punch is screwed by a screw and an upper ultrasonic horn, and the lower end of the upper punch passes through the upper die during operation
  • the lower end of the lower punch is connected by a screw and a lower ultrasonic horn, and the upper end of the lower punch passes through
  • the lower ultrasonic vibration mechanism includes a lower ultrasonic flange fixing plate, a lower ultrasonic pressure plate, a lower ultrasonic horn, a lower ultrasonic fixed plate, a lower ultrasonic transducer, and a lower rod.
  • the upper end of the upper ultrasonic horn and the upper ultrasonic transducer are screwed, and the upper ultrasonic flange fixing plate and the upper ultrasonic pressure plate are pressed by the upper hexagonal screw to the upper ultrasonic horn
  • the upper ultrasonic flange fixing plate and the upper ultrasonic pressure plate are in contact with the flange of the upper ultrasonic horn, and there is a gap between the hole on the upper ultrasonic flange fixing plate and the cylindrical surface of the upper ultrasonic horn
  • a pull-up bar is disposed between the upper ultrasonic flange fixing plate and the upper ultrasonic fixing plate.
  • the lower end of the lower ultrasonic horn and the lower ultrasonic transducer are connected by screwing, and the lower ultrasonic flange fixing plate and the lower ultrasonic pressing plate are pressed by the hexagonal screw to the lower ultrasonic horn.
  • the lower ultrasonic flange fixing plate and the lower ultrasonic pressure plate are in contact with the flange of the lower ultrasonic horn, and the hole on the lower ultrasonic flange fixing plate and the cylindrical surface of the lower ultrasonic horn have a gap, and the lower ultrasonic A pull rod is disposed between the flange fixing plate and the lower ultrasonic fixing plate.
  • the upper concave die, the lower concave die, the upper concave die and the lower concave die sleeve are installed by prestressing, and the upper concave die sleeve and the upper die pad plate are connected by bolts and fixed on the upper punching cushion sleeve, and the upper punching is performed.
  • the cushion sleeve is pressed on the upper template by the upper mold seat plate, and the lower mold sleeve and the lower mold cushion plate are fixed by bolting and fixed on the lower punching cushion sleeve, and the lower punching cushion sleeve is pressed on the lower template through the lower mold base plate, and the upper mold base is pressed.
  • the plate and the lower die plate are respectively fixed by bolts with the upper plate and the lower plate.
  • Ultrasonic vibration is added during the precision forging process, and stress waves are generated on the blank; when the ultrasonic stress wave propagates on the blank, the blank is under the action of alternating load; when the high-energy short-wave phonon propagates to the deformation zone, high-density dislocation At grain boundaries, phonons are blocked by discontinuous structures, and phonons of various frequencies collide with atoms in these regions, producing new, higher-energy phonons whose energy is the sum of the energy of each phonon. This energy and the transitions that lead to the kinetic and potential energies of the atoms in these regions reduce the blocking effect of these regions on plastic deformation while increasing the local temperature.
  • the phonon selectively exhibits the characteristics of dislocation accumulation regions inside the deformation zone, so that the deformation zone metal exhibits extremely high plasticity and low deformation resistance.
  • the phonon energy will eventually be converted into the plastic deformation energy of the material.
  • the internal particles of the billet absorb the vibration energy and the motion is intensified, resulting in thermal softening associated with dislocations, causing the dynamic deformation resistance of the material to decrease.
  • the vibrational action diversifies the internal stress direction of the material, making the new slip system easier to form, and the slip system is increased.
  • the blank By controlling the amplitude, frequency and vibration mode of the ultrasonic vibration, the blank is in the ultrasonic vibration during the forging process, improving the plastic deformation ability of the metal, greatly reducing the deformation resistance of the metal, and reducing the lateral pressure of the metal on the cavity. Reduce or avoid defects such as cracks, cracks, scratches, etc. during the forging process, and reduce the difference in stability between different batches of products;
  • Ultrasonic vibration and pressure coupling can reduce the grain size, refine the micro-grain structure of metal fiber, and make the refinement degree of each part more uniform; it can alleviate or eliminate the stress concentration phenomenon in the severe deformation zone of the relief tool, and make the stress distribution more uniform. , effectively improve the surface quality, reduce the roughness of the forming surface; open the ultrasonic vibration when the lower punch ejects the part, can reduce the bonding force between the part and the mold, and improve the demoulding ability;
  • Figure 1 is a view of an ultrasonic assisted precision forging device
  • FIG. 2 is a connection structural view of the ultrasonic horn and the flange fixing plate and the pressure plate of FIG. 1;
  • FIG. 3 is a schematic diagram of a stress-strain field of an upper ultrasonic vibration mechanism
  • Figure 4 is a schematic view showing the coupling of forging pressure and ultrasonic vibration
  • Figure 5 is a diagram of an ultrasonic assisted conventional forging device.
  • hexagon socket screw 30. pressure plate; 32. horn; 33. fixed rod; 34. tool head; 35. upper mold; 36. upper insert; 37. lower mold; 38. lower insert; 39. ejector; End tool head; 41. ejector end horn; 42. ejector end transducer; 43. Hexagon socket head cap screw.
  • Embodiment 1 Ultrasonic vibration assisted precision forging, ultrasonic assisted precision forging device, as shown in FIG. 1, includes upper concave die 2, lower concave die 25, upper punch 12, lower punch 23, upper ultrasonic vibration mechanism and lower ultrasonic
  • the vibration mechanism, the stress-strain field of the upper ultrasonic vibration system is schematically shown in conjunction with FIG. 3, and the upper ultrasonic vibration mechanism is composed of an upper ultrasonic flange fixing plate 6, an upper ultrasonic pressure plate 7, an upper ultrasonic horn 8, and an ultrasonic exchange.
  • the energy device 9, the upper ultrasonic fixing plate 10 and the upper pull rod 11 are composed, and the lower ultrasonic vibration mechanism is composed of a lower ultrasonic flange fixing plate 17, a lower ultrasonic pressing plate 18, a lower ultrasonic horn 19, a lower ultrasonic fixing plate 20, and a lower ultrasonic transducer
  • the upper punch 12 is fixedly connected by a screw and an upper ultrasonic horn 8.
  • the lower end passes through the upper die 2
  • the lower punch 23 is fixed by the screw and the lower ultrasonic horn 19.
  • the upper end passes through the lower die 25; when the die is closed, the upper and lower die 2, 25 together with the upper punch 12 and the lower punch 23 constitute a closed cavity.
  • the upper ultrasonic horn 8 and the upper ultrasonic transducer 9 are screwed, and the upper ultrasonic flange fixing plate 6 and the upper ultrasonic pressure plate 7 are pressed by the hexagon socket screws on both sides of the flange of the upper ultrasonic horn 8
  • the upper ultrasonic flange fixing plate 6 and the upper ultrasonic pressure plate 7 are only in contact with the flange of the upper ultrasonic horn 8, and are not in contact with the cylindrical surface of the upper ultrasonic horn 8, as shown in Fig. 2, the upper ultrasonic flange is fixed.
  • the plate 6 is connected by the upper pull rod 11, the nut and the upper ultrasonic fixing plate 10; in the lower ultrasonic vibration mechanism, the lower ultrasonic horn 19 and the lower ultrasonic transducer 21 are screwed, the lower ultrasonic flange fixing plate 17 and the lower
  • the ultrasonic pressure plate 18 is pressed on both sides of the flange of the lower ultrasonic horn 19 by a hexagon socket screw, and the lower ultrasonic flange fixing plate 17 and the lower ultrasonic pressure plate 18 are only in contact with the flange of the lower ultrasonic horn 19, and
  • the cylindrical surface of the ultrasonic horn 19 is in contact with the lower ultrasonic flange fixing plate 17 through the pull-down rod 22, the nut and the lower ultrasonic fixing plate 20; the upper and lower concave molds 2, 25 and the upper and lower concave mold sleeves 1, 26 is installed by prestressing, and the upper die sleeve 1 and the upper die pad 3 are bolted and fixed on the upper On the cushion cover 4,
  • the ultrasonic vibration frequency is 20KHz
  • the ultrasonic vibration power is set (the ultrasonic vibration amplitude is adjusted to 40 ⁇ m)
  • the sandwich type of the piezoelectric ceramic stack is tangentially polarized.
  • Longitudinal torsional ultrasonic transducer or selected with a spiral groove-exponential segment output, the ultrasonic vibration mode is longitudinal torsional vibration;
  • the mold clamping cylinder is locked, and the upper and lower ultrasonic vibration mechanisms connected to the upper punch 12 and the lower punch 23 are opened at the same time, the upper punch 12 is further pressed down, and the lower punch 23 is further pressed to form Parts, pressure for 3 seconds;
  • the ultrasonic vibration on the upper punch 12 and the lower punch 23 is closed, and the upper mold portion is ascended. After the mold is opened, the ultrasonic vibration mechanism on the side of the lower punch 23 is opened, the vibration time is 1 second, and the lower punch 23 is moved upward to the gear forging top. Out.
  • the ultrasonic assisted ordinary forging device is combined with the press machine, the forming mold, the ultrasonic vibration mechanism, and the jack ejecting mechanism, wherein the forming mold is composed of the upper mold 35, the lower mold 37, the upper insert 36 and the lower portion.
  • the insert block 38 is formed.
  • the upper insert block 36 is connected by a thread and a tool head 34.
  • a gap is left between the upper insert block 36 and the upper mold 35.
  • the lower insert block 38 and the lower mold 37 are fixedly connected by a hexagon socket screw 43.
  • the ultrasonic vibration mechanism is composed of an ultrasonic generator, a transducer 31, a horn 32, a tool head 34 and a fixing device, and the tool head 34 passes through the screw and
  • the horn 32 is fixedly connected, and the horn 32 is fixedly connected by the screw and the transducer 31.
  • the flange fixing plate 28 and the pressure plate 30 are pressed by the hexagon socket screw 29 on both sides of the flange of the horn 32, the flange The fixing plate 28 and the pressing plate 30 are only in contact with the flange of the horn 32, and cannot be in contact with the cylindrical surface of the horn 32.
  • the flange fixing plate 28 is fixedly connected by the fixing rod 33 and the upper mold 35;
  • the ejector lever 39, the ejector end tool head 40, the ejector end horn 42 and the ejector end transducing 41, the jack 39 and the jack end tool head 40 are connected by a screw, and the jack end tool head 40 and the jack end horn 42 are connected by a screw, and the jack end horn 42 and the jack end transducer 41 Connected by thread.
  • the billet is heated to the forging temperature, rough punching is performed on the forging equipment, and then the counterbore is performed on the reaming machine;
  • the ultrasonic vibration frequency is selected according to the material, type, size and forming temperature of a gear forging, 20 KHz
  • the ultrasonic vibration device starts to clamp the mold, and the mold is completely close to hold for 3 seconds to make the vibration transmission more fully.
  • the coupling force between the forging pressure and the ultrasonic vibration is shown in Fig.
  • the ultrasonic vibration on the insert is closed, and the mold is opened; Open the ultrasonic vibration device on the side of the ejector for 2 seconds (the ultrasonic vibration frequency is 15KHz, the ultrasonic vibration amplitude is 10 ⁇ m, the vibration mode is longitudinal vibration), the ejector will push out the forging, close the ejector end ultrasonic vibration device, and the ejector rod is reset.

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  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

一种超声辅助精锻装置，包括上凹模（2）、下凹模（25）、上冲头（12）、下冲头（23）、上超声振动机构和下超声振动机构；将超声振动机构穿过冲垫套（4,15）、模板（5,16）中间的通槽与冲头（12,23）固定连接，变幅杆（8,19）将放大后的超声振动传递给冲头，冲头再将振动传递给坯料，通过改变超声振动的频率、振幅、振动模式和冲头的形状、尺寸来适用于不同产品的精锻，还涉及一种超声辅助精锻方法，该方法大幅提高了金属的塑性变形能力，提高金属填充性，减小了坯料与模具之间的摩擦力，细化晶粒组织，降低成形表面的粗糙度，提高了锻件的脱模能力，适用性广，提高了材料利用率和产品合格率。

Description

超声辅助精锻方法与装置 技术领域
本发明涉及精锻领域，特别涉及到超声振动辅助精锻的方法与装置。
背景技术
锻造工业一直是汽车、矿山、能源、建筑、航天、兵器等工业的重要基础。第二次世界大战以后，随着现代化大规模生产的发展，各种少无切削新工艺应运而生。近几十年来，锻压工艺突破了毛坯生产的范畴，人们能生产出不少接近成品的锻压成形件，其表面质量好，机械加工余量少、尺寸精度高。精锻成形提高了材料利用率，部分取消或减少了切削加工，使金属纤维沿产品轮廓连续分布，使零件的承载能力增加，提高整体性能。
现有精锻生产技术主要有热精锻、温精锻和冷精锻等几种工艺方法。塑性成形方法中的锻造、挤压等工艺存在变形力过大、制件成形轮廓不精确、金属填充性不好、模具寿命低及成形后脱模困难等缺点。
以齿轮精锻为例：弧齿锥齿轮的弧齿结构特殊，不能做到弧形齿面一步精锻成形，弧齿锥齿轮热精锻及冷精整形复合工艺(专利公开号CN102441773A)采用热精锻成形、等温球化退火、喷砂、去飞边和冷精整形工序制造，提高了材料利用率，提高了产品质量，但工序繁多，锻压过程中存在不完全填充现象，存在锻压的产品出模比较困难的问题，而且冷精整形阶段齿形精整模具局部受力较大，使得模具的寿命降低。
弧齿锥齿轮精锻成型制造方法(专利公开号CN102240774A)是将料段加热至1150-1180℃，再墩粗、冲孔、扩环、预锻、终锻，球化退火处理，表面喷砂清理，表面磷化皂化，最后进行常温精整齿形；该工艺方法工序较多，加工成本较高，存在锻压应力过大使得制件出现内部断裂的现象，在常温精整齿形阶段，多余金属的侧向流动很容易将模具上的弧齿齿形破坏，或将产品的弧齿破坏，导致模具的寿命非常短。
齿轮温精锻工艺方法(专利公开号CN1799726A)对钢坯料加热温度介于热精锻和冷精锻之间，在此温度条件下，钢坯料表面除有少量氧化外不发生脱碳现象，制造工序少，综合制造成本低，但是精度、质量、机械强度，锻模的使用寿命也介于热精锻和冷精锻工艺之间。
一种渗碳钢20CrMnTi为材料的齿轮热精锻加工工艺(专利公开号CN102764838A)采用墩粗拔长、制坯、锻模、去毛边、锻后处理(包括淬火、调质热处理，齿面热处理 通过渗氮、表面淬火、正火、喷砂去除氧化皮、表面酸处理)、齿形冷精整的锻造工艺，该工艺方法简化了齿轮锻造工艺过程，减少了生产工序，提高了模具的使用寿命，但是存在变形力过大、成形齿廓不精确及成形后脱模困难的问题。
上海交通大学庄新存等人通过超声辅助1050铝合金压缩试验，发现成形力降低程度与超声振幅成正比，工件与模具之间的摩擦减小，提高了工件表面质量。张杨设计了超声-压力耦合进行挤压铸造铝合金的装置，研究发现超声振动和压力耦合可以减小晶粒尺寸，增加等轴晶组织的比例，并且各取样位置的细化程度比较均匀。美国北卡罗来纳州立大学Bunget等人将超声振动应用于微挤压过程中，研制了超声振动辅助微挤压实验系统可实现正挤压、前杯挤压和双杯挤压，实验结果表明，超声振动能大幅降低成形力，在正挤压中降低18％，前杯挤压中降低25％，双杯挤压中降低23％；并能大幅提高工件表面光洁度。V.C.Kumar等人研究了超声振动金属塑性成形的表面层效应，研究发现，沿材料成形方向或垂直方向施加超声振动，可以有效得减小工模间摩擦，且当超声振动沿材料成形方向时，呈现出最佳的降低摩擦力效果。综上所述，将超声振动加入金属的塑性成形中会有改善工件表面质量，减小工具和模具之间的摩擦，细化晶粒尺寸，降低工件成形力，提高工件表面光洁度等明显效果。
虽然很多专利和技术试图通过优化工艺过程来改善锻件质量，减少生产成本，但是仍然存在变形力过大、制件成形轮廓不精确、金属填充性不好、模具寿命低及成形后脱模困难等问题。本发明通过在精锻过程中加入超声振动进行辅助，可以减小坯料与模具之间的接触摩擦系数；细化金属纤维微观晶粒组织，使得制件各位置的晶粒细化程度较均匀；缓解或消除工具剧烈变形区应力集中现象，使应力分布更均匀，降低制件成形表面的粗糙度；减少或避免制件在锻造过程中出现裂纹、裂缝、刮伤等缺陷。
发明内容
根据上述问题，本发明在精锻过程中加入超声振动进行辅助成形，使坯料在挤压精锻过程处于超声振动之中，大幅降低金属的变形抗力，减少或避免制件在精锻过程中出现裂纹、裂缝、刮伤等缺陷；降低坯料与模具之间的接触摩擦系数，提高金属的填充性，使制件的成形轮廓更精确；超声振动和压力耦合可减小晶粒尺寸，细化金属纤维微观晶粒组织，降低制件成形表面的粗糙度。
本发明是通过如下技术方案得以实现的：
超声辅助精锻方法，在常规的精锻模具上设置超声振动机构，使上超声振动机构穿过上冲垫套、上模板中间的通槽与上冲头固定连接，上超声换能器将电信号转换成机械 振动并传递给上超声变幅杆，上超声变幅杆将放大后的超声振动传递给上冲头，上冲头再将振动传递给坯料，使产生谐振的上冲头将超声振动传递给坯料，下超声振动机构与上超声振动机构相同，同样的，使下超声振动机构穿过下冲垫套、下模板中间的通槽与上冲头固定连接，下超声换能器将电信号转换成机械振动并传递给下超声变幅杆，下超声变幅杆将放大后的超声振动传递给下冲头，下冲头再将振动传递给坯料，使产生谐振的下冲头将超声振动传递给坯料；
通过调节超声振动的振幅、频率和振动模式，适用于不同条件下的精锻成形；在下冲头顶出制件时开启超声振动，可以减小锻件和模具之间的结合力，提高脱模能力，包括如下步骤：
步骤S1：首先根据锻件的材料、形状复杂程度、尺寸大小和成形温度等选择超声振动频率，调节超声振动功率即调节超声振动振幅，通过更换换能器或变幅杆来产生合适的超声振动模式，仿真计算并设计冲头的长度为
Figure PCTCN2018095532-appb-000001
波长，冲头的固有频率为超声振动频率；
步骤S2：将上超声振动机构、下超声振动机构分别与上冲头、下冲头固定连接，并将其安装到精锻模具上，使上冲头、下冲头穿过上凹模、下凹模上开设的通槽，将前期处理过的毛坯放入模具中，压力机工作，上超声振动机构下行，开始合模；
步骤S3：上凹模、下凹模闭合后，合模缸锁紧，同时开启与上冲头、下冲头相连的上超声振动机构、下超声振动机构，上冲头进一步下压，下冲头进一步上压，成形制件，保压；
步骤S4：关闭上冲头、下冲头上的超声振动，上凹模部分上行，开模后开启下冲头一侧的超声振动机构，通过下冲头上行将锻件顶出。
进一步的，超声辅助精锻时超声波发生器频率的范围为15KHz-80KHz；超声波振幅范围为5μm-80μm；超声波在精锻过程中采用的振动模式有径向振动、纵向振动、弯曲振动、纵扭振动、纵弯振动或者弯扭振动。
进一步的，下冲头顶出制件时，设置在下冲头上的超声振动频率的可选范围是15KHz-50KHz；超声波振幅范围为5μm-50μm；采用的超声振动模式有纵向振动、弯曲振动、纵扭振动、纵弯振动或者弯扭振动。
进一步的，上冲头、下冲头的长度
Figure PCTCN2018095532-appb-000002
其中，λ为超声波在冲头材料中 的传播波长，c为超声波在冲头材料中的传播声速，f为超声波频率。
进一步的，在锻造过程中可对锻件一侧端面施加超声振动，也可对两侧端面同时施加超声振动，也可对局部区域施加超声振动；所述上超声变幅杆和上冲头、下超声变幅杆和下冲头采用螺柱连接或采用直接接触的形式传递超声振动。
超声辅助精锻方法的装置，包括上凹模、下凹模、上冲头、下冲头、上超声振动机构和下超声振动机构，模具闭合时，所述上凹模、下凹模与上冲头和下冲头一起组成闭式模腔；所述上超声振动机构和下超声振动机构结构相同，且上下对称分布；所述上超声振动机构包括上超声法兰固定板、上超声压板、上超声变幅杆、上超声换能器、上超声固定板和上拉杆；所述上冲头的上端通过螺杆和上超声变幅杆螺纹连接，工作时上冲头的下端穿过上凹模，下冲头的下端通过螺杆和下超声变幅杆螺栓连接，工作时下冲头的上端穿过下凹模。
进一步的，所述下超声振动机构包括下超声法兰固定板、下超声压板、下超声变幅杆、下超声固定板、下超声换能器和下拉杆。
进一步的，所述上超声振动机构中，上超声变幅杆的上端和上超声换能器通过螺纹连接，上超声法兰固定板和上超声压板通过内六角螺钉压紧在上超声变幅杆的法兰盘两侧，上超声法兰固定板和上超声压板与上超声变幅杆的法兰接触，上超声法兰固定板上的孔与上超声变幅杆的圆柱面之间有间隙；上超声法兰固定板与上超声固定板之间设置有上拉杆。
进一步的，所述下超声振动机构中，下超声变幅杆的下端和下超声换能器通过螺纹连接，下超声法兰固定板和下超声压板通过内六角螺钉压紧在下超声变幅杆的法兰盘两侧，下超声法兰固定板和下超声压板与下超声变幅杆的法兰接触，下超声法兰固定板上的孔和下超声变幅杆的圆柱面有间隙，下超声法兰固定板与下超声固定板之间设置有下拉杆。
进一步的，所述上凹模、下凹模与上凹模、下凹模套通过预应力配合安装，上凹模套、上模垫板通过螺栓连接后固定在上冲垫套上，上冲垫套通过上模座板压在上模板上，下凹模套、下模垫板通过螺栓连接后固定在下冲垫套上，下冲垫套通过下模座板压在下模板上，上模座板、下模座板用螺栓分别与上模板、下模板固定。
有益效果：
1.在精锻过程中加入超声振动，坯料上产生应力波；超声应力波在坯料上传播时，坯料处在交变载荷的作用下；当高能的短波声子传播到变形区高密度位错晶界时，声子 受到不连续结构的阻隔，各种频率的声子在这些区域与原子碰撞，产生新的、能量更高的声子，其能量是各碰撞声子的能量和。该能量和导致这些区域原子动能和势能的跃迁，并降低这些区域对塑性变形的阻塞作用，同时使局部温度升高。声子这种有选择性的积聚在变形区内部的位错塞积区域的特性，使得变形区金属表现出极高的塑性和较低的变形抗力。在压力载荷的协同作用下，声子能最终将转化为材料的塑性变形能。坯料内部微粒吸收振动能量后运动加剧，产生与位错相关的热致软化，引起材料的动态变形阻力下降。此外，振动除了提供能量提高原子活性外，其扰力作用使材料内部应力方向多样化，使新的滑移系更容易形成，滑移系增加，在静态载荷和振动载荷的交替作用下，那些具有明显扩散特性的塑性变形机构(滑移、孪晶等)更容易发挥作用。在精锻成形中，真实接触面积取决于法向力，对接触面的摩擦大小有直接的影响。叠加高频振动后，真实接触面积会发生波动，导致平均径向摩擦力减小，高频振动引发的界面摩擦降低与界面上的相对振动相关，相对振动使接触面的相对速度提高，导致摩擦减小。
2.通过控制超声振动的振幅、频率和振动模式，使坯料在锻造过程中处于超声振动之中，提高金属的塑性变形能力，大幅降低金属的变形抗力，减少金属对模腔的侧向压力，减少或避免制件在锻造过程中出现裂纹、裂缝、刮伤等缺陷，减小了不同批次的产品之间的稳定性差异；
3.减小坯料与模具之间的接触摩擦系数，通过改变超声振动模式，增强金属在某个方向或轨迹上的流动性能，提高金属的填充性，使锻件的成形轮廓更精确，提高锻件的承载能力和服役寿命；
4.超声振动和压力耦合可以减小晶粒尺寸，细化金属纤维微观晶粒组织，各部位的细化程度较均匀；可以缓解或消除缓解工具剧烈变形区应力集中现象，使应力分布更均匀，有效改善表面质量，降低成形表面的粗糙度；在下冲头顶出制件时开启超声振动，可以减小制件和模具之间的结合力，提高脱模能力；
5.可通过改变超声振动的振幅、频率和振动模式来适用于不同形状、不同尺寸、不同材料、不同成形温度的坯料的精锻，可通过改变超声振动的振幅、频率和振动模式来适用于热精锻、温精锻、冷精锻或普通锻造；降低精锻压力机的吨位，降低模具要求，提高精锻模具的使用寿命，提高生产效率，提高材料利用率，提高了的合格率，减少能源消耗，减少生产设备的资金投入和后期的维修、保养费用。
附图说明
图1为超声辅助精锻装置图；
图2为图1中的超声波变幅杆和和法兰固定板、压板的连接结构图；
图3为上超声振动机构的应力-应变场示意图；
图4为锻压力和超声振动的耦合示意图；
图5为超声辅助普通锻造装置图。
附图标记如下：
1.上凹模套；2.上凹模；3.上模垫板；4.上冲垫套；5.上模板；6.上超声法兰固定板；7.上超声压板；8.上超声变幅杆；9.上超声换能器；10.上超声固定板；11.上拉杆；12.上冲头；13.上模座板；14.下模座板；15.下冲垫套；16.下模板；17.下超声法兰固定板；18.下超声压板；19.下超声变幅杆；20.下超声固定板；21.下超声换能器；22.下拉杆；23.下冲头；24.下模垫板；25.下凹模；26.下凹模套；27.锻件；28.法兰固定板；29.内六角螺钉；30.压板；31.换能器；32.变幅杆；33.固定杆；34.工具头；35.上模；36.上镶块；37.下模；38.下镶块；39.顶杆；40.顶杆端工具头；41.顶杆端变幅杆；42.顶杆端换能器；43.内六角螺钉。
具体实施方式
为了使本发明的上述目的、特征和优点能够更清楚表达，下面结合附图对本发明的具体实施方式作详细说明。
实施例一超声振动辅助精锻，超声辅助精锻装置，结合附图1所示，包括上凹模2、下凹模25、上冲头12、下冲头23、上超声振动机构和下超声振动机构，上超声振动系统的应力-应变场示意结合附图3所示，所述上超声振动机构由上超声法兰固定板6、上超声压板7、上超声变幅杆8、上超声换能器9、上超声固定板10、上拉杆11组成，下超声振动机构由下超声法兰固定板17、下超声压板18、下超声变幅杆19、下超声固定板20、下超声换能器21、下拉杆22组成；所述上冲头12通过螺杆和上超声变幅杆8固定连接，工作时下端穿过上凹模2，下冲头23通过螺杆和下超声变幅杆19固定连接，工作时上端穿过下凹模25；模具闭合时，上、下凹模2、25与上冲头12和下冲头23一起组成闭式模腔。
其中，上超声变幅杆8和上超声换能器9通过螺纹连接，上超声法兰固定板6和上超声压板7通过内六角螺钉压紧在上超声变幅杆8的法兰盘两侧，上超声法兰固定板6和上超声压板7只和上超声变幅杆8的法兰接触，不和上超声变幅杆8的圆柱面接触，如图2所示，上超声法兰固定板6通过上拉杆11、螺母和上超声固定板10连接；所述下超声振动机构中，下超声变幅杆19和下超声换能器21通过螺纹连接，下超声法兰固定 板17和下超声压板18通过内六角螺钉压紧在下超声变幅杆19的法兰盘两侧，下超声法兰固定板17和下超声压板18只和下超声变幅杆19的法兰接触，不和下超声变幅杆19的圆柱面接触，下超声法兰固定板17通过下拉杆22、螺母和下超声固定板20连接；所述上、下凹模2、25与上、下凹模套1、26通过预应力配合安装，上凹模套1、上模垫板3通过螺栓连接后固定在上冲垫套4上，上冲垫套4通过上模座板13压在上模板5上，下凹模套26、下模垫板24通过螺栓连接后固定在下冲垫套15上，下冲垫套15通过下模座板14压在下模板16上，上模座板13、下模座板14用螺栓分别与上、下模板5、16固定。
首先根据某弧齿锥齿轮的材料、形状、尺寸和成形温度等选择超声振动频率为20KHz，设置超声振动功率(调节超声振动振幅为40μm)，选择将压电陶瓷堆切向极化的夹心式纵扭超声换能器或选择带有螺旋槽-指数段输出端的，超声振动模式为纵扭振动；
将前期处理过的毛坯放入模具中，压力机工作，上模部分下行，开始合模；
上下凹模闭合后，合模缸锁紧，同时开启与上冲头12、下冲头23相连的上、下超声振动机构，上冲头12进一步下压，下冲头23进一步上压，成形制件，保压3秒；
关闭上冲头12、下冲头23上的超声振动，上模部分上行，开模后开启下冲头23一侧的超声振动机构，振动时间为1秒，下冲头23上行将齿轮锻件顶出。
实施例二(超声振动辅助普通锻造，结合附图5)
超声辅助普通锻造的装置结合附图5所示，是由压力机、成形模具、超声振动机构、顶杆顶出机构组成，其中成形模具由上模35、下模37、上镶块36和下镶块38组成，上镶块36通过螺纹和工具头34连接，上镶块36和上模35之间留有一定间隙，下镶块38和下模37通过内六角螺钉43固定连接，上模35、下模37分别固定在压力机的动横梁、下横梁上；超声振动机构由超声波发生器、换能器31、变幅杆32、工具头34和固定装置组成，工具头34通过螺杆和变幅杆32固定连接，变幅杆32通过螺杆和换能器31固定连接，法兰固定板28和压板30通过内六角螺钉29压紧在变幅杆32的法兰盘两侧，法兰固定板28和压板30只和变幅杆32的法兰接触，不能和变幅杆32的圆柱面接触，法兰固定板28通过固定杆33和上模35固定连接；顶杆顶出机构由顶杆39、顶杆端工具头40、顶杆端变幅杆42、顶杆端换能器41组成，顶杆39和顶杆端工具头40通过螺杆连接，顶杆端工具头40和顶杆端变幅杆42通过螺杆连接，顶杆端变幅杆42和顶杆端 换能器41通过螺纹连接。
首先将坯料加热至锻造温度、在锻压设备上作墩粗冲孔加工，接着在扩孔机上作扩孔辗压；根据某齿轮锻件的材料、种类、尺寸和成形温度等选择超声振动频率为20KHz，设置好超声振动振幅为30μm，选择常规压电陶瓷换能器和圆锥型变幅杆进行安装，超声振动模式为纵向振动；将毛坯放入锻造模具中，开启压力机，同时开启镶块上的超声振动装置，开始合模，模具完全贴紧后保持3秒，使振动传递更充分，锻压力和超声振动的耦合力示意如图3所示；关闭镶块上的超声振动，开模；开启顶杆一侧的超声振动装置2秒(超声振动频率为15KHz，超声振动振幅为10μm，振动模式为纵向振动)，顶杆将锻件顶出，关闭顶杆端超声振动装置，顶杆复位。
所述实施例为本发明的优选的实施方式，但本发明并不限于上述实施方式，在不背离本发明的实质内容的情况下，本领域技术人员能够做出的任何显而易见的改进、替换或变型均属于本发明的保护范围。

Claims (10)

  1. 超声辅助精锻方法，其特征在于，在常规的精锻模具上设置超声振动机构，使上超声振动机构穿过上冲垫套(4)、上模板(5)中间的通槽与上冲头(12)固定连接，上超声换能器(9)将电信号转换成机械振动并传递给上超声变幅杆(8)，上超声变幅杆(8)将放大后的超声振动传递给上冲头(12)，上冲头(12)再将振动传递给坯料，使产生谐振的上冲头(12)将超声振动传递给坯料，下超声振动机构与上超声振动机构相同，同样的，使下超声振动机构穿过下冲垫套(15)、下模板(16)中间的通槽与下冲头(23)固定连接，下超声换能器(21)将电信号转换成机械振动并传递给下超声变幅杆(19)，下超声变幅杆(19)将放大后的超声振动传递给下冲头(23)，下冲头(23)再将振动传递给坯料，使产生谐振的下冲头(23)将超声振动传递给坯料；
    通过调节超声振动的振幅、频率和振动模式，适用于不同条件下的精锻成形；在下冲头(23)顶出制件时开启超声振动，以减小锻件和模具之间的结合力，提高脱模能力，包括如下步骤：
    步骤S1：首先根据锻件的材料、形状复杂程度、尺寸大小和成形温度等选择超声振动频率，调节超声振动功率即调节超声振动振幅，通过更换换能器或变幅杆来产生合适的超声振动模式，仿真计算并设计冲头的长度为
    Figure PCTCN2018095532-appb-100001
    波长，冲头的固有频率为超声振动频率；
    步骤S2：将上超声振动机构、下超声振动机构分别与上冲头(12)、下冲头(23)固定连接，并将其安装到精锻模具上，使上冲头(12)、下冲头(23)穿过上凹模(2)、下凹模(25)上开设的通槽，将前期处理过的毛坯放入模具中，压力机工作，上超声振动机构下行，开始合模；
    步骤S3：上凹模(2)、下凹模(25)闭合后，合模缸锁紧，同时开启与上冲头(12)、下冲头(23)相连的上超声振动机构、下超声振动机构，上冲头(12)进一步下压，下冲头(23)进一步上压，成形制件，保压；
    步骤S4：关闭上冲头(12)、下冲头(23)上的超声振动，上凹模(2)部分上行，开模后开启下冲头(23)一侧的超声振动机构，通过下冲头(23)上行将锻件顶出。
  2. 根据权利要求1所述的超声辅助精锻方法，其特征在于，超声辅助精锻时超声波发生器频率的范围为15KHz-80KHz；超声波振幅范围为5μm-80μm；超声波在精锻过程中采用的振动模式有径向振动、纵向振动、弯曲振动、纵扭振动、纵弯振动或者弯扭振动。
  3. 根据权利要求1所述的超声辅助精锻方法，其特征在于，下冲头(23)顶出制件 时，设置在下冲头(23)上的超声振动频率的范围是15KHz-50KHz；超声波振幅范围为5μm-50μm；采用的超声振动模式有纵向振动、弯曲振动、纵扭振动、纵弯振动或者弯扭振动。
  4. 根据权利要求1所述的超声辅助精锻方法，其特征在于上冲头(12)、下冲头(23)的长度
    Figure PCTCN2018095532-appb-100002
    其中，λ为超声波在冲头材料中的传播波长，c为超声波在冲头材料中的传播声速，f为超声波频率。
  5. 根据权利要求1所述的超声辅助精锻方法，其特征在于，在锻造过程中可对锻件一侧端面施加超声振动，或者对两侧端面同时施加超声振动，或者对局部区域施加超声振动；所述上超声变幅杆(8)和上冲头(12)、下超声变幅杆(19)和下冲头(23)采用螺柱连接或者采用直接接触的形式传递超声振动。
  6. 根据权利要求1至5任一项所述的超声辅助精锻方法的装置，包括上凹模(2)、下凹模(25)、上冲头(12)、下冲头(23)、上超声振动机构和下超声振动机构，其特征在于，模具闭合时，所述上凹模(2)、下凹模(25)与上冲头(12)和下冲头(23)一起组成闭式模腔；所述上超声振动机构和下超声振动机构结构相同，且上下对称分布；所述上超声振动机构包括上超声法兰固定板(6)、上超声压板(7)、上超声变幅杆(8)、上超声换能器(9)、上超声固定板(10)和上拉杆(11)；所述上冲头(12)的上端通过螺杆和上超声变幅杆(8)螺纹连接，工作时上冲头(12)的下端穿过上凹模(2)，下冲头(23)的下端通过螺杆和下超声变幅杆(19)螺栓连接，工作时下冲头(23)的上端穿过下凹模(25)。
  7. 根据权利要求6所述的超声辅助精锻装置，其特征在于，所述下超声振动机构包括下超声法兰固定板(17)、下超声压板(18)、下超声变幅杆(19)、下超声固定板(20)、下超声换能器(21)和下拉杆(22)。
  8. 根据权利要求6所述的超声辅助精锻装置，其特征在于，所述上超声振动机构中，上超声变幅杆(8)的上端和上超声换能器(9)通过螺纹连接，上超声法兰固定板(6)和上超声压板(7)通过内六角螺钉压紧在上超声变幅杆(8)的法兰盘两侧，上超声法兰固定板(6)和上超声压板(7)与上超声变幅杆(8)的法兰接触，上超声法兰固定板(6)上的孔与上超声变幅杆(8)的圆柱面之间有间隙；上超声法兰固定板(6)与上超声固定板(10)之间设置有上拉杆(11)。
  9. 根据权利要求6所述的超声辅助精锻装置，其特征在于，所述下超声振动机构中，下超声变幅杆(19)的下端和下超声换能器(21)通过螺纹连接，下超声法兰固定板 (17)和下超声压板(18)通过内六角螺钉压紧在下超声变幅杆(19)的法兰盘两侧，下超声法兰固定板(17)和下超声压板(18)与下超声变幅杆(19)的法兰接触，下超声法兰固定板(17)上的孔和下超声变幅杆(19)的圆柱面有间隙，下超声法兰固定板(17)与下超声固定板(20)之间设置有下拉杆(22)。
  10. 根据权利要求6所述的超声辅助精锻装置，其特征在于，所述上凹模(2)、下凹模(25)与上凹模(1)、下凹模套(26)通过预应力配合安装，上凹模套(1)、上模垫板(3)通过螺栓连接后固定在上冲垫套(4)上，上冲垫套(4)通过上模座板(13)压在上模板(5)上，下凹模套(26)、下模垫板(24)通过螺栓连接后固定在下冲垫套(15)上，下冲垫套(15)通过下模座板(14)压在下模板(16)上，上模座板(13)、下模座板(14)用螺栓分别与上模板(5)、下模板(16)固定。
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