WO2020232775A1 - 一种型腔表层随形网状结构热锻模具及其制备方法 - Google Patents

一种型腔表层随形网状结构热锻模具及其制备方法 Download PDF

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WO2020232775A1
WO2020232775A1 PCT/CN2019/091095 CN2019091095W WO2020232775A1 WO 2020232775 A1 WO2020232775 A1 WO 2020232775A1 CN 2019091095 W CN2019091095 W CN 2019091095W WO 2020232775 A1 WO2020232775 A1 WO 2020232775A1
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layer
mold
transition layer
surfacing
soft material
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PCT/CN2019/091095
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English (en)
French (fr)
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张建生
周杰
甘玉平
张谦
王秋韵
杨绿峰
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重庆杰品科技股份有限公司
重庆大学
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Priority to US17/044,202 priority Critical patent/US11465195B2/en
Publication of WO2020232775A1 publication Critical patent/WO2020232775A1/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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/26—Methods of annealing
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/84—Controlled slow cooling
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • 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
    • B23P6/00—Restoring or reconditioning objects
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2251/00—Treating composite or clad material
    • C21D2251/04—Welded or brazed overlays
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2261/00—Machining or cutting being involved
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/007—Heat treatment of ferrous alloys containing Co

Definitions

  • the invention relates to a large-scale hot forging die, in particular to a large-scale hot forging die with a conformal network structure on the surface of a cavity and a preparation method thereof, and belongs to the technical field of molds.
  • ZL 201510171656.4 sets a sandwich layer between the cast steel matrix and the transition layer.
  • the sandwich layer has better plasticity and lower yield strength than both the cast steel matrix and the transition layer.
  • the sandwich layer is The transition layer and the cast steel substrate act as a soft cushion, which makes the stress distribution on the cast steel substrate layer more uniform, rapidly diffuses and weakens the high-pressure peak stress, reduces the peak stress of the cast steel substrate, and avoids direct peak stress. This leads to cracks in the cast steel matrix, resulting in mold fracture failure, thereby improving the pressure safety of the cast steel matrix, and improving the pressure bearing capacity and overall safety performance of the sandwich layer mold.
  • the purpose of the present invention is to provide a large hot forging die with a conformal network structure on the surface of the cavity and a preparation method thereof.
  • the large forging die can well prevent the cavity
  • the formation and propagation of surface cracks increase the life of the forging die.
  • a hot forging die for a cavity surface layer conforming to a mesh structure comprising a die base.
  • a sandwich layer, a transition layer and a strengthening layer are sequentially formed on the die base.
  • the strengthening layer is divided into a plurality of mutually separated by structural strengthening layer grooves In the small unit, all the reinforced layer grooves are interconnected in a mesh structure, and the reinforced layer grooves are filled with high temperature resistant soft materials.
  • transition layer is divided into several small units separated from each other by constructing transition layer grooves, all transition layer grooves are interconnected and interconnected in a network structure, and ordinary soft materials are filled in the transition layer grooves;
  • the trenches of the layer and the trenches of the strengthening layer are completely opposite to each other.
  • the hardness of the ordinary soft material is HRC 10-30, and the mechanical properties at room temperature are: yield strength ⁇ s ⁇ 550MPa, tensile strength ⁇ b ⁇ 750MPa, elongation ⁇ 14.7%, shrinkage rate ⁇ 31.2%, impact energy Akv ⁇ 30J, compressive strength at 400°C ⁇ 550MPa; hardness of high temperature resistant soft material is HRC 20-35, mechanical properties at room temperature are: yield strength ⁇ s ⁇ 700MPa, tensile strength ⁇ b ⁇ 980MPa, elongation ⁇ 16.6%, shrinkage ⁇ 31.5%, impact energy Akv ⁇ 35J, compressive strength at 600°C ⁇ 500MPa.
  • the method for preparing a hot forging die with a conformal network structure on the surface of the cavity includes the following steps:
  • Cast steel is used as the base material of the mold to cast the base of the mold to be welded; among them, the surplus welding allowance is reserved at the cavity;
  • step 1) on the base of the mold to be welded, which has been poured, along the shape of the reserved surfacing area, surfacing welding consumables for the sandwich layer with good plasticity and low yield strength;
  • step 2) weld the sandwich layer on the mold base, cover all the sandwich layer welding consumables along the margin shape of the reserved surfacing weld and the shape of the sandwich layer, the transition layer welding material with higher surfacing strength and hardness Wrap it and continue welding to the pre-designed thickness under the contour of the mold cavity;
  • step 3) on the mold base with the transition layer welded, according to the pre-designed transition layer groove network structure, the corresponding transition layer groove network structure is processed, and the depth of the transition layer groove corresponds to the thickness of the transition layer ;
  • step 4 use ordinary soft material with good plasticity and high elongation to fill up by surfacing, and the filling thickness is consistent with the thickness of the transition layer, so that the surface of the ordinary soft material is flush with the surface of the transition layer ;
  • step 5) the transition layer and the surface of the ordinary soft material, the high temperature and wear-resistant reinforced layer welding material is surfacing, covering the main wear-resistant working area or all wear-resistant areas of the mold, and welded to the pre-designed thickness on the cavity contour ;
  • step 6) on the mold base where the strengthening layer is welded, according to the pre-designed strengthening layer groove network structure, the corresponding strengthening layer groove network structure is processed, and the depth of the strengthening layer groove corresponds to the thickness of the strengthening layer ;
  • the high temperature resistant soft material is used for surfacing filling, and the filling thickness is consistent with the thickness of the reinforced layer, so that the surface of the high temperature resistant soft material is flush with the surface of the reinforced layer;
  • step 8) The mold obtained in step 8) is subjected to a tempering and slow cooling process, mechanical processing and other post-processing procedures to obtain a large-scale hot forging mold with a conformal network structure on the surface of the cavity according to claim 2.
  • Cast steel is used as the base material of the mold to cast the base of the mold to be welded; among them, the surplus welding allowance is reserved at the cavity;
  • step 1) on the base of the mold to be welded, which has been poured, along the shape of the reserved surfacing area, surfacing welding consumables for the sandwich layer with good plasticity and low yield strength;
  • step 2) weld the sandwich layer on the mold base, cover all the sandwich layer welding consumables along the margin shape of the reserved surfacing weld and the shape of the sandwich layer, the transition layer welding material with higher surfacing strength and hardness Wrap it and continue welding to the pre-designed thickness under the contour of the mold cavity;
  • step 3) on the surface of the transition layer welding material, surfacing welding with high temperature and wear-resistant reinforced layer welding material, covering the main wear-resistant working area or all wear-resistant areas of the mold, and welding to the pre-designed thickness of the cavity contour;
  • step 4 On the mold base of step 4), according to the pre-designed mesh groove structure, process the corresponding mesh groove structure, the depth of the groove and the surface of the sandwich layer welding material;
  • step 5 In the reticulated groove structure of step 5), firstly use ordinary soft material with good plasticity and high elongation to be surfacing and filling.
  • the filling thickness of the ordinary soft material is consistent with the thickness of the transition layer, so that the surface of the ordinary soft material is consistent with the thickness of the transition layer.
  • the surface of the transition layer is flush; then it is filled with high temperature resistant soft material by surfacing, and the filling thickness of the high temperature resistant soft material is consistent with the thickness of the reinforced layer, so that the surface of the high temperature resistant soft material is flush with the surface of the reinforced layer;
  • step 6) The mold obtained in step 6) is subjected to a tempering and slow cooling process, mechanical processing and other post-processing procedures to obtain a large-scale hot forging mold with a conformal network structure on the surface of the cavity according to claim 2.
  • the present invention has the following beneficial effects:
  • the present invention constructs grooves of a certain width on the surface of the large-scale mold cavity (all grooves are interconnected to form a mesh groove), thereby dividing the large-area surface cavity of the mold into small-area cavities, thereby eliminating
  • the ordered cracks are constructed into ordered mesh grooves, and then soft materials are filled in the mesh grooves.
  • the filled mesh-like high elongation soft material and the reinforced layer block high temperature and deformation resistant hard material are combined to obtain a soft and hard combination ,
  • the strong and tough matching cavity surface, the ordered mesh groove and the filled soft material can fully release the larger tensile stress that may occur on the mold cavity surface during the welding process and the future mold service conditions, thereby effectively avoiding cracks
  • the formation and expansion of forging dies extend the life of large forging dies and turn passive into active.
  • Figure 1 is a schematic diagram of the cross-sectional structure of the forging die of the present invention.
  • the crack of the present invention is a penetrating elongated crack on the surface of a large forging mold cavity caused by alternating thermal stress.
  • the crack is not a fatigue crack or a superficial crack, so the traditional solutions based on fatigue cracks or superficial cracks are not Suitable for this large forging die.
  • the present invention proposes the idea of reticulation, referred to as reticulation (grid-like high elongation soft material and block resistant The combination of high temperature and deformation-resistant hard materials obtains a soft and hard combination, strong and tough matching cavity surface).
  • the surface layer of the cavity of the present invention is a large-scale hot forging die with a conformal network structure, including a die base A, on which a sandwich layer B and a transition layer are sequentially formed C and a strengthening layer D, the strengthening layer D is separated into several small units separated from each other by the strengthening layer grooves, all the strengthening layer grooves are interconnected and interconnected in a network structure, and the strengthening layer grooves are filled with high temperature resistant soft material F.
  • the combination of the strengthening layer material and the high temperature resistant soft material of the present invention can obtain a soft-hard combined, strong-tough matching cavity surface layer, which can fully release the larger tensile stress that may occur on the mold cavity surface during the welding process and under the mold service conditions .
  • the service temperature of the transition layer is still very high. If only grooves are provided on the strengthening layer and filled, the accumulation of thermal stress may lead to internal cracks. In view of this, in order to achieve a better effect of preventing the appearance of surface cracks, the transition layer C of the present invention is separated and filled with grooves according to the concept of the strengthening layer, that is, the transition layer C is separated into a number of each other by the transition layer grooves. In the isolated small unit, all the transition layer grooves are interconnected in a mesh structure, and the transition layer grooves are filled with ordinary soft material E; all the transition layer grooves and the strengthening layer grooves are completely opposite.
  • the groove setting position is generally based on the statistical data of the mold cavity groove area and the crack occurrence area during the actual service process of the same type of mold, that is, the large principle is to set the groove according to the crack appearance path, and set a reasonable size interval and position when setting it. That's it (related to the size of the mold cavity); the width is about 5mm (consider processing convenience and effect).
  • the shape of the groove There are no special requirements for the shape of the groove. Generally, after gouging, it has a fish-scale semicircular cross-section.
  • the hardness of the ordinary soft material E is HRC 10-30, and the mechanical properties at room temperature are: yield strength ⁇ s ⁇ 550MPa, tensile strength ⁇ b ⁇ 750MPa, elongation ⁇ 14.7%, shrinkage rate ⁇ 31.2%, impact Work Akv ⁇ 30J, compressive strength at 400°C (working temperature) ⁇ 550MPa; hardness of high temperature resistant soft material F is HRC 20-35; mechanical properties at room temperature are: yield strength ⁇ s ⁇ 700MPa, tensile strength ⁇ b ⁇ 980MPa, elongation ⁇ 16.6%, shrinkage rate ⁇ 31.5%, impact energy Akv ⁇ 35J, compressive strength at 600°C (working temperature) ⁇ 500MPa.
  • the same soft material namely ordinary soft material E
  • the temperature is high (hard-to-deform materials, such as titanium alloys, high-temperature alloys, etc., the surface temperature of the cavity can reach 600-700°C), if the strengthening layer groove is still filled with ordinary soft materials, it will collapse and deform rapidly, which is more than cracks More serious failures, so the present invention meets the above requirements for the high temperature resistant soft material F filled in the trenches of the strengthening layer.
  • the present invention is improved on the basis of the patent application number 201510171656.4 and the invention titled "A method for preparing sandwich layer forging die and forging die sandwich layer surfacing".
  • the patent introduces the mechanical performance index of sandwich layer B: ⁇ s yield strength ⁇ 550MPa, ⁇ b tensile strength ⁇ 760MPa, ⁇ elongation ⁇ 14.7%, ⁇ shrinkage ⁇ 31.2%, hardness 30 ⁇ 35HRC; preferably the ⁇ elongation of sandwich layer B is 14.7% ⁇ 20%, ⁇ shrinks The rate is 31.2% to 36%, and the ⁇ s yield strength is 550 to 570MPA.
  • the mechanical properties of the transition layer C ⁇ s yield strength ⁇ 790MPa, ⁇ b tensile strength ⁇ 1100MPa, ⁇ elongation ⁇ 11.7%, ⁇ shrinkage ⁇ 28.9%, hardness 45-50HRC; strengthening layer D mechanical performance indicators: ⁇ s Yield strength ⁇ 1000MPa, ⁇ b tensile strength ⁇ 1400MPa, ⁇ elongation ⁇ 9.6%, ⁇ shrinkage ⁇ 26.5%, hardness 50 ⁇ 55HRC. The above indicators are also suitable for this application.
  • the hardness of the sandwich layer material used in the present invention can also be greatly reduced to 10-30HRC, the plasticity index is basically unchanged, and the sandwich layer can be consistent with ordinary soft material E when the working temperature is below 500°C; after long-term industrialization
  • the strengthening layer material is actually changed to a cobalt-based superalloy material, which has moderate hardness at room temperature (easy for machining to obtain precise dimensions), and has a strengthening effect at high temperature to maintain good strength; the composition/structure transition between the materials is good, Achieve effective metallurgical bonding.
  • the weld groove In order to release the great alternating thermal tensile stress and other stresses on the surface of the large forging die, the weld groove needs to be filled with soft material; and in order to prevent the blank from being pressed into the weld groove area of the soft material layer during the high temperature forming process , It is necessary to surfacing a layer of high-temperature-resistant soft material that is harder than ordinary soft materials on the upper surface of the soft material layer, thus designing a gradient filling method for the mesh weld groove, and comparing the corresponding material Carry out optimal design and matching.
  • the present invention makes a creative contribution to the prior art in the structure of the mold of the present invention, rather than in the selection of the shape and type of the forging die and the selection of the base material of the forging die, the following preparation methods in this specific embodiment only list A specific preparation method for forging dies, but the following steps should be regarded as suitable for different shapes and types of forging dies and various forging die base materials.
  • the method for preparing a large-scale hot forging die with a conformal network structure on the surface of the cavity includes the following steps:
  • the surface layer of the forging model cavity is designed with a mesh structure and a grid groove (due to the need for surfacing filler material in the groove, so It can also be called weld groove) position design;
  • step 2) weld the sandwich layer welding material with good plasticity along the pre-designed shape on the mold base A to be welded at the place where the welding margin is reserved, and weld it to about 15mm below the contour line of the mold cavity.
  • step 3 On the basis of step 3), overlay the transition layer material on the mold base where the sandwich layer material has been welded, and weld it to about 5mm below the contour of the mold cavity to obtain the transition layer C;
  • step 4 On the basis of step 4), on the mold base where the transition layer material is welded, surfacing the surface strengthening layer material, welding to about 3mm on the contour line of the cavity, to obtain the strengthening layer D;
  • step 5 On the basis of step 5), according to the mesh structure design requirements in step 1), a grid-like groove is constructed in the gradient surfacing layer; the depth of the groove reaches the surface of the sandwich layer welding material;
  • step 6 On the basis of step 6), the common soft material E is surfacing and filled in the grid groove first, and welded to be flush with the surface of the transition layer, and then the high temperature resistant soft material is surfacing on the common soft material E Material F, welded to be flush with the surface of the strengthening layer;
  • the forging die after surfacing welding is subjected to a slow cooling process after tempering, where the tempering temperature is 550°C, slowly cooling to 180°C, after slow cooling, the forging die is placed in the air to cool to room temperature;
  • G is the final cavity contour line.
  • the above preparation process is to uniformly construct the trench after the transition layer and the strengthening layer are all overlaid, and then fill with different soft materials or the same soft material layer by layer according to the needs; it can also be layered and filled and then carried out. , That is, the transition layer is built up first, then the transition layer trench is constructed, and then the transition layer trench is filled; then the reinforcement layer is built up, then the reinforcement layer trench is constructed, and then the reinforcement layer trench is filled.
  • the groove (weld groove) is generally constructed by gouging.
  • the present invention proposes a new method of mesh structure design for the gradient surface layer (strengthened layer and transition layer) of the cast steel matrix forging model cavity to prepare large forging dies, which mainly includes mesh structured partition and block design method, mesh Structured network structure and block structure design method, network structured material optimization design and matching method.
  • the present invention fills the pre-designed grid weld groove with a soft material with good plasticity and high elongation, and allows the soft material to deform to a certain extent to release the thermal stress of each surfacing block, which can effectively solve the problem The problem of cracks on the surface of the large forging die cavity.
  • the grid-like weld groove adopts a gradient combination of ordinary soft materials and high-temperature-resistant soft materials, which can significantly enhance the high-temperature resistance of the mold , Anti-cracking and anti-cracking ability, improve the service life of forging dies; if applied to the preparation of large forging dies for forming materials with a forming temperature below 500 °C, the grid-like weld groove can be made of a single common soft material, which can also be significant Improve the service life of forging dies.
  • the present invention enables the use of low-cost materials for the cast steel matrix, and can realize lightweight and low-cost manufacturing of large forging dies.
  • the method of the present invention can be widely applied to the manufacture of large molds and fixtures such as forging dies, stamping dies, edge wrapping machines, edge wrapping dies, fixtures, etc., and has broad application value and development prospects in the field of green manufacturing.
  • the invention can not only be used for the preparation of new molds, but also suitable for the repair and remanufacturing of large forging dies for forming difficult-to-deform materials. It can significantly extend the life of the forging dies and prevent the formation and expansion of cracks; the method allows the mold steel matrix to be repeated Utilization can realize resource saving and material recycling, which meets the national green manufacturing requirements.
  • the following is an example of repairing and rebuilding a used mold.
  • step 2) On the basis of step 2), another layer of transition layer material with a height of 15mm is built-up on the surface of the sandwich layer material;
  • step 3 On the basis of step 3), a layer of high temperature resistant strengthening layer material with a height of 12mm is welded on the surface of the transition layer material, of which 2mm is the machining allowance;
  • step 4 On the basis of step 4), according to the design requirements in step 1), construct a mesh weld groove with a height of 27mm for the transition layer material and the high temperature strengthened layer material;
  • step 5 On the basis of step 5), the groove of the mesh weld is first filled with ordinary soft material with a height of 15mm, and then a layer of high temperature resistance with a height of 12mm is welded on the ordinary soft material Soft materials, 2mm is the machining allowance;
  • Tempering the forging die after surfacing where the tempering temperature is 550°C, and the temperature is slowly cooled to 180°C. After slow cooling, place the mold in the air for air cooling to room temperature;

Abstract

一种型腔表层随形网状结构热锻模具，其包括模具基体（A），在模具基体上依次形成有夹心层（B）、过渡层（C）和强化层（D），所述强化层和过渡层通过沟槽分隔为若干小单元，所有沟槽互联互通呈网状结构，在过渡层沟槽中填充有普通软质材料（E）；在强化层沟槽中填充有耐高温软质材料（F）。以及一种上述热锻模具的制备方法。所述热锻模具中的强化层材料和耐高温软质材料相结合能够获得软硬结合、强韧匹配的型腔表层，可充分释放模具型腔表面在焊接过程以及在模具服役条件下可能出现的较大拉应力，避免焊接过程及服役过程中出现的热裂纹。

Description

一种型腔表层随形网状结构热锻模具及其制备方法 技术领域
本发明涉及大型热锻模具，具体涉及一种型腔表层随形网状结构大型热锻模具及其制备方法，属于模具技术领域。
背景技术
随着我国航空航天、核电、石化等国家战略需求领域的迅速发展，对大型化、整体化、精密化的高性能关键构件的需求日益增加，这些构件的加工往往涉及大型锻模。大型锻模加工对象及加工中面临的复杂恶劣环境往往使其寿命很低、成本很高。中国发明专利“一种基于铸钢基体的双金属层堆焊制备锻模的方法(ZL200910104604X)”和“一种夹心层锻模及锻模夹心层堆焊的制备方法(ZL 201510171656.4)”在一定程度上较好地解决了大型锻模生产成本高、使用寿命低的难题。其中ZL 201510171656.4在铸钢基体和过渡层之间设置一层夹心层，所述夹心层较铸钢基体和过渡层两者塑性更好，屈服强度更低；当模具承受高压应力时，夹心层在过渡层与铸钢基体之间起着软垫作用，使铸钢基体层上的应力分布更加均匀，将高压峰值应力迅速扩散减弱，使铸钢基体承受的峰值应力值得以降低，避免峰值应力直接导致铸钢基体产生裂纹，造成模具断裂失效，从而提高铸钢基体的承压安全性、提高夹心层模具的承压能力和整体安全性能。虽然上述专利在一定程度上解决了寿命和耐压的问题，但由于大型锻模往往涉及难变形材料的加工，随着产量的增加，难变形材料成形用大型锻模在生产了数十件锻件后，型腔表层还是会出现众多长条形不规则裂纹，并影响大型锻模寿命、模锻安全生产和高端装备制造成本及国际竞争力，解决这些裂纹是当前大型模锻件生产新的急待解决的瓶颈。究其原因，国内外由传统方法制造的锻模，因型腔面积大，在服役前后某些环节，如模具制造时的堆焊环节、模具投入使用生产构件时的高温环节，这些环节温度应力都非常大，从而导致锻模型腔表面在使用时间久后会不同程度产生大量裂纹。
发明内容
针对现有大型锻模型腔表层容易出现裂纹的不足，本发明的目的在于提出一种型腔表层随形网状结构大型热锻模具及其制备方法，本大型锻模能够很好地防止型腔表层裂纹的形成和扩展，提高锻模寿命。
本发明的技术方案是这样实现的：
一种型腔表层随形网状结构热锻模具，包括模具基体，在模具基体上依次形成有夹心层、过渡层和强化层，所述强化层通过构造强化层沟槽被分隔为若干彼此隔断的小单元， 所有强化层沟槽互联互通呈网状结构，在强化层沟槽中填充有耐高温软质材料。
进一步地，所述过渡层通过构造过渡层沟槽被分隔为若干彼此隔断的小单元，所有过渡层沟槽互联互通呈网状结构，在过渡层沟槽中填充有普通软质材料；所有过渡层沟槽与强化层沟槽上下完全正对。
所述普通软质材料的硬度为HRC 10-30，在常温下力学性能为：屈服强度σs≥550MPa，抗拉度σb≥750MPa，延伸率δ≥14.7％，收缩率Ψ≥31.2％，冲击功Akv≥30J，400℃时的压缩强度≥550MPa；耐高温软质材料的硬度为HRC 20-35，在常温下力学性能为：屈服强度σs≥700MPa，抗拉强度σb≥980MPa，延伸率δ≥16.6％，收缩率Ψ≥31.5％，冲击功Akv≥35J，600℃下压缩强度≥500MPa。
上述型腔表层随形网状结构热锻模具的制备方法，包括如下步骤：
1)采用铸钢作为模具基体材料浇注出待焊模具基体；其中，型腔部位预留堆焊余量；
2)在步骤1)浇注好的待焊模具基体上，沿预留堆焊处的形状，堆焊塑性好且屈服强度低的夹心层焊材；
3)在步骤2)焊好夹心层的模具基体上，沿预留堆焊处余量形状以及夹心层的形状，堆焊强度和硬度较高的过渡层焊材，将夹心层焊材全部覆盖包住，并继续焊至模具型腔轮廓线下预先设计厚度处；
4)在步骤3)焊好过渡层的模具基体上，按照预先设计的过渡层沟槽网状结构，加工出对应的过渡层沟槽网状结构，过渡层沟槽的深度与过渡层厚度对应；
5)在步骤4)的过渡层沟槽中，用塑性好、延伸率高的普通软质材料进行堆焊填充，填充厚度与过渡层厚度一致，使普通软质材料表面与过渡层表面平齐；
6)在步骤5)过渡层和普通软质材料表面，堆焊高温耐磨的强化层焊材，覆盖模具主要耐磨工作区域或全部耐磨区域，焊至型腔轮廓线上预先设计厚度处；
7)在步骤6)焊好强化层的模具基体上，按照预先设计的强化层沟槽网状结构，加工出对应的强化层沟槽网状结构，强化层沟槽的深度与强化层厚度对应；
8)在步骤7)的强化层沟槽中，用耐高温软质材料进行堆焊填充，填充厚度与强化层厚度一致，使耐高温软质材料表面与强化层表面平齐；
9)将步骤8)得到的模具进行回火缓冷工艺、机械加工及其他后处理工序，即得权利要求2所述型腔表层随形网状结构化大型热锻模具。
也可以过渡层和强化层堆焊好后，一次性构造沟槽，再分别填充。具体如下：
1)采用铸钢作为模具基体材料浇注出待焊模具基体；其中，型腔部位预留堆焊余量；
2)在步骤1)浇注好的待焊模具基体上，沿预留堆焊处的形状，堆焊塑性好且屈服强度低的夹心层焊材；
3)在步骤2)焊好夹心层的模具基体上，沿预留堆焊处余量形状以及夹心层的形状，堆焊强度和硬度较高的过渡层焊材，将夹心层焊材全部覆盖包住，并继续焊至模具型腔轮廓线下预先设计厚度处；
4)在步骤3)过渡层焊材表面，堆焊高温耐磨的强化层焊材，覆盖模具主要耐磨工作区域或全部耐磨区域，焊至型腔轮廓线上预先设计厚度处；
5)在步骤4)的模具基体上，按照预先设计的网状沟槽结构，加工出对应的网状沟槽结构，沟槽的深度及达夹心层焊材表面；
6)在步骤5)的网状沟槽结构中，先用塑性好、延伸率高的普通软质材料堆焊填充，普通软质材料填充厚度与过渡层厚度一致，使普通软质材料表面与过渡层表面平齐；然后再用耐高温软质材料堆焊填充，耐高温软质材料填充厚度与强化层厚度一致，使耐高温软质材料表面与强化层表面平齐；
7)将步骤6)得到的模具进行回火缓冷工艺、机械加工及其他后处理工序，即得权利要求2所述型腔表层随形网状结构化大型热锻模具。
相比现有技术，本发明具有如下有益效果：
本发明通过在大型模具型腔表层随形构建一定宽度的沟槽(所有沟槽互联互通而成网沟)，由此将模具大面积表层型腔分块化为小面积型腔，从而把无序的裂纹构建成有序的网沟，然后在网沟中填充软质材料，填充的网格状高延伸率软质材料和强化层块状耐高温抗变形硬质材料相结合获得软硬结合、强韧匹配的型腔表层，构建的有序网沟及填充的软质材料可充分释放模具型腔表面在焊接过程以及在未来模具服役条件下可能出现的较大拉应力，从而有效避免裂纹的形成与扩展，延长大型锻模的寿命，化被动为主动。
附图说明
图1为本发明锻模截面结构示意图；
图中，A为模具基体；B为夹心层；C为过渡层；D为强化层；E为普通软质材料；F为耐高温软质材料；G为型腔轮廓线。
具体实施方式
本发明的裂纹是交变热应力导致的大型锻模型腔表层出现的贯穿性长条形裂纹，该裂纹不属于疲劳裂纹或浅表裂纹，所以传统的基于疲劳裂纹或浅表裂纹解决方案均不适用本大型锻模。为了从根本上解决长条形裂纹的形成与扩展问题，通过分析裂纹的形成机制后， 本发明特提出网构化思路，简称网构化(网格状高延伸率软质材料和块状耐高温抗变形硬质材料结合获得软硬结合、强韧匹配的型腔表层)。
具体实现结构可以参见图1，从图上可以看出，本发明型腔表层随形网状结构化大型热锻模具，包括模具基体A，在模具基体A上依次形成有夹心层B、过渡层C和强化层D，所述强化层D通过强化层沟槽分隔为若干彼此隔断的小单元，所有强化层沟槽互联互通呈网状结构，在强化层沟槽中填充有耐高温软质材料F。本发明强化层材料和耐高温软质材料相结合能够获得软硬结合、强韧匹配的型腔表层，可充分释放模具型腔表面在焊接过程以及在模具服役条件下可能出现的较大拉应力。
对于难变形材料锻造过程，过渡层服役温度依然很高，如果只在强化层上设置沟槽并填充，热应力集聚可能导致内部裂纹萌生。鉴于此，为了达到更好的防止表层裂纹出现的效果，本发明过渡层C按强化层的构思进行了同样的分隔和沟槽填充，即所述过渡层C通过过渡层沟槽分隔为若干彼此隔断的小单元，所有过渡层沟槽互联互通呈网状结构，在过渡层沟槽中填充有普通软质材料E；所有过渡层沟槽与强化层沟槽上下完全正对。
沟槽设置位置一般以模具型腔凹槽区及同类型模具实际服役过程中裂纹出现区域统计数据为基础，即大的原则按裂纹出现路径设置沟槽，具体设置时，设置合理尺寸间隔和位置即可(和模具型腔尺寸相关)；宽度为5mm左右(考虑加工方便性和效果)。沟槽形状没有特殊要求，一般气刨后为鱼鳞状半圆形截面。
所述普通软质材料E的硬度为HRC 10-30，常温下的力学性能为：屈服强度σs≥550MPa，抗拉强度σb≥750MPa，延伸率δ≥14.7％，收缩率Ψ≥31.2％，冲击功Akv≥30J，400℃(工作温度)时的压缩强度≥550MPa；耐高温软质材料F的硬度为HRC 20-35；在常温下的力学性能为：屈服强度σs≥700MPa，抗拉强度σb≥980MPa，延伸率δ≥16.6％，收缩率Ψ≥31.5％，冲击功Akv≥35J，600℃(工作温度)下压缩强度≥500MPa。在工作温度不高于500℃的前提下(如铝合金锻件成形用的锻模，型腔表层温度最高只有400℃左右)，可考虑选用同种软质材料，即普通软质材料E。温度高时(难变形材料，如钛合金、高温合金等，型腔表层温度能够达到600-700℃)，如果强化层沟槽仍然填充普通软质材料，会迅速压塌变形，这是比裂纹更严重的失效，所以本发明对强化层沟槽填充的耐高温软质材料F进行了上述要求。
本发明以申请号201510171656.4、发明名称为“一种夹心层锻模及锻模夹心层堆焊的制备方法”的专利为基础进行改进，该专利中介绍到,夹心层B的力学性能指标：σ s屈服强度≥550MPa，σ b抗拉强度≥760MPa，δ延伸率≥14.7％，ψ收缩率≥31.2％，硬度30～ 35HRC；优选夹心层B的δ延伸率为14.7％～20％，ψ收缩率为31.2％～36％，σs屈服强度为550～570MPA。过渡层C力学性能指标：σ s屈服强度≥790MPa，σ b抗拉强度≥1100MPa，δ延伸率≥11.7％，ψ收缩率≥28.9％，硬度45～50HRC；强化层D力学性能指标：σ s屈服强度≥1000MPa，σ b抗拉强度≥1400MPa，δ延伸率≥9.6％，ψ收缩率≥26.5％，硬度50～55HRC。上述指标同样适合本申请。实际操作中，本发明所用夹心层材料硬度还可以大幅降低，降低到10～30HRC，塑性指标基本不变，工作温度在500℃以下时夹心层可以与普通软质材料E一致；经长期产业化试验，强化层材料实际改用钴基高温合金材料，常温下硬度适中(便于机加工获得精确尺寸)，而高温下具有强化效应能够保持良好的强度；各材料之间成分/组织过渡良好，能够实现有效的冶金结合。
为了释放大型锻模表层很大的交变热拉应力及其他应力，焊缝坡口中需填充软质材料；又为了避免模具在高温成型过程中坯料压入软质材料层的焊缝坡口区，需在软质材料层的上表层堆焊一层耐高温的相较普通软质材料较硬些的软质材料，从而设计了网状焊缝坡口的梯度填充方法，并对相应的材料进行优选设计与匹配。
因本发明对现有技术作出创造性贡献的地方在于本发明模具的结构，而不是在于锻模形状和种类的选择以及锻模基体材料的选择，故本具体实施方式中下述制备方法只列举了一种具体的锻模对应的制备方法，但是以下的各步骤对于不同形状和种类的锻模以及各种锻模基体材料，均应视为是适合的。
上述型腔表层随形网状结构化大型热锻模具的制备方法，包括如下步骤：
1)采用模拟仿真技术，根据锻模在使用工况下的应力应变分布规律，对锻模型腔表层进行网状结构化设计及网格状沟槽(由于沟槽内需要堆焊填充材料，所以也可称作焊缝坡口)位置设计；
2)采用铸钢作为锻模基体材料浇注出待焊模具基体A，其中，型腔部位预留堆焊余量厚度20mm，对浇注出的模具基体进行淬火、回火处理；
3)在步骤2)的基础上，在待焊模具基体A上沿预先设计形状在预留堆焊余量处堆焊塑性好的夹心层焊材，焊至模具型腔轮廓线下15mm左右，得到夹心层B；
4)在步骤3)的基础上，在已焊夹心层材料的模具基体上，堆焊过渡层材料，焊至模具型腔轮廓线下5mm左右，得到过渡层C；
5)在步骤4)的基础上，在焊好过渡层材料的模具基体上，堆焊表面强化层材料，焊至型腔轮廓线上3mm左右，得到强化层D；
6)在步骤5)的基础上，按步骤1)中的网状结构化设计要求在梯度堆焊层构造网格状沟槽；沟槽的深度及达夹心层焊材表面；
7)在步骤6)的基础上，在网格状沟槽中先堆焊填充普通软质材料E，焊至与过渡层表面齐平，然后在普通软质材料E上堆焊耐高温软质材料F，并焊至与强化层表面齐平；
8)将堆焊完毕后的锻模进行回火后缓冷工艺，其中回火温度为550℃，缓冷至180℃，缓冷后，将锻模放置在空气中空冷至室温；
9)对空冷后的锻模进行机械加工，使锻模各部分尺寸到位，制得实际生产所需锻模，G为最后得到的型腔轮廓线。
上述制备工艺是在过渡层和强化层全部堆焊后再统一进行沟槽构建，然后根据需要逐层填充不同的软质材料或者相同的软质材料；也可以分层分隔填充再进行上一层，即先堆焊过渡层，然后构建过渡层沟槽，再对过渡层沟槽进行填充；再堆焊强化层，然后构建强化层沟槽，再对强化层沟槽进行填充。本发明中沟槽(焊缝坡口)一般通过气刨方式构造。
相比其他锻模制造技术，本发明的特点在于：
1)本发明提出对铸钢基体锻模型腔梯度表层(强化层和过渡层)进行网状结构化设计以制备大型锻模的新方法，主要包括网状结构化分区分块设计方法、网状结构化网状结构和块状结构设计方法、网状结构化材料优选设计与匹配方法。
2)本发明在预先设计的网格状焊缝坡口中填充塑性好、延伸率高的软质材料，并允许软质材料发生一定变形使各堆焊分块的热应力得到释放，可有效解决大型锻模型腔表层出现裂纹的问题。
3)本发明若应用于高温难变形材料成形用大型锻模的制备，网格状的焊缝坡口采用普通软质材料与耐高温软质材料的梯度结合，能够显著增强模具的耐高温能力、防裂止裂能力，提高锻模使用寿命；若应用于成形温度低于500℃材料成形用大型锻模的制备，网格状的焊缝坡口可采用单一普通软质材料，同样能够显著提高锻模使用寿命。
4)本发明使铸钢基体低成本材料得以利用，可以实现大型锻模轻量化和低成本制造。
5)本发明方法可推广应用于锻模、冲压模、包边机和包边模、夹具等大型模具、夹具的制造，在绿色制造领域具有广阔的应用价值和发展前景。
本发明除了可以用于新模具的制备，也适用于难变形材料成形用大型锻模的修复与再制造，能够显著延长锻模的寿命，防止裂纹形成与扩展；本方法使模具钢基体得以重复利用，可实现资源的节约和材料的循环使用，符合国家绿色制造的要求。以下为一个废旧模具修复再造实施例。
1)采用模拟仿真技术，根据锻模在使用工况下的应力应变分布规律，对锻模型腔表层进行网构化设计及网状焊缝坡口位置设计，焊缝坡口深度为锻模型腔表面以下25mm，并去除型腔表层裂纹，预留堆焊余量30mm；
2)在待修复锻模基体表面上堆焊一层高度为5mm的夹心层材料；
3)在步骤2)的基础上，在夹心层材料的表面再堆焊一层高度为15mm的过渡层材料；
4)在步骤3)的基础上，在过渡层材料的表面再堆焊一层高度为12mm的耐高温强化层材料，其中2mm为加工余量；
5)在步骤4)的基础上，按照步骤1)中的设计要求对过渡层材料和耐高温强化层材料进行高度为27mm的网状焊缝坡口构建；
6)在步骤5)的基础上，对网状焊缝坡口先用普通软质材料进行高度为15mm的堆焊填充，然后在普通软质材料上再堆焊一层高度为12mm的耐高温软质材料，其中2mm为加工余量；
7)将堆焊后的锻模进行回火，其中回火温度为550℃，缓冷温度至180℃。缓冷后，将模具放置在空气中进行空冷至室温；
8)对冷却后的锻模进行机械加工，保证各部分的尺寸精度，即完成锻模的修复。
最后需要说明的是，本发明的上述实施例仅仅是为说明本发明所作的举例，而并非是对本发明的实施方式的限定。尽管申请人参照较佳实施例对本发明进行了详细说明，对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其他不同形式的变化和变动。这里无法对所有的实施方式予以穷举。凡是属于本发明的技术方案所引申出的显而易见的变化或变动仍处于本发明的保护范围之列。

Claims (5)

  1. 一种型腔表层随形网状结构热锻模具，包括模具基体，在模具基体上依次形成有夹心层、过渡层和强化层，其特征在于：所述强化层通过构造强化层沟槽被分隔为若干彼此隔断的小单元，所有强化层沟槽互联互通呈网状结构，在强化层沟槽中填充有耐高温软质材料。
  2. 根据权利要求1所述的型腔表层随形网状结构热锻模具，其特征在于：所述过渡层通过构造过渡层沟槽被分隔为若干彼此隔断的小单元，所有过渡层沟槽互联互通呈网状结构，在过渡层沟槽中填充有普通软质材料；所有过渡层沟槽与强化层沟槽上下完全正对。
  3. 根据权利要求2所述的型腔表层随形网状结构热锻模具，其特征在于：所述普通软质材料的硬度为HRC 10-30，在常温下力学性能为：屈服强度σs≥550MPa，抗拉度σb≥750MPa，延伸率δ≥14.7％，收缩率Ψ≥31.2％，冲击功Akv≥30J，400℃时的压缩强度≥550MPa；耐高温软质材料的硬度为HRC 20-35，在常温下力学性能为：屈服强度σs≥700MPa，抗拉强度σb≥980MPa，延伸率δ≥16.6％，收缩率Ψ≥31.5％，冲击功Akv≥35J，600℃下压缩强度≥500MPa。
  4. 权利要求2所述型腔表层随形网状结构热锻模具的制备方法，其特征在于：包括如下步骤：
    1)采用铸钢作为模具基体材料浇注出待焊模具基体；其中，型腔部位预留堆焊余量；
    2)在步骤1)浇注好的待焊模具基体上，沿预留堆焊处的形状，堆焊塑性好且屈服强度低的夹心层焊材；
    3)在步骤2)焊好夹心层的模具基体上，沿预留堆焊处余量形状以及夹心层的形状，堆焊强度和硬度较高的过渡层焊材，将夹心层焊材全部覆盖包住，并继续焊至模具型腔轮廓线下预先设计厚度处；
    4)在步骤3)焊好过渡层的模具基体上，按照预先设计的过渡层沟槽网状结构，加工出对应的过渡层沟槽网状结构，过渡层沟槽的深度与过渡层厚度对应；
    5)在步骤4)的过渡层沟槽中，用塑性好、延伸率高的普通软质材料进行堆焊填充，填充厚度与过渡层厚度一致，使普通软质材料表面与过渡层表面平齐；
    6)在步骤5)过渡层和普通软质材料表面，堆焊高温耐磨的强化层焊材，覆盖模具主要耐磨工作区域或全部耐磨区域，焊至型腔轮廓线上预先设计厚度处；
    7)在步骤6)焊好强化层的模具基体上，按照预先设计的强化层沟槽网状结构，加工出对应的强化层沟槽网状结构，强化层沟槽的深度与强化层厚度对应；
    8)在步骤7)的强化层沟槽中，用耐高温软质材料进行堆焊填充，填充厚度与强化层 厚度一致，使耐高温软质材料表面与强化层表面平齐；
    9)将步骤8)得到的模具进行回火缓冷工艺、机械加工及其他后处理工序，即得权利要求2所述型腔表层随形网状结构化大型热锻模具。
  5. 权利要求2所述型腔表层随形网状结构热锻模具的制备方法，其特征在于：包括如下步骤：
    1)采用铸钢作为模具基体材料浇注出待焊模具基体；其中，型腔部位预留堆焊余量；
    2)在步骤1)浇注好的待焊模具基体上，沿预留堆焊处的形状，堆焊塑性好且屈服强度低的夹心层焊材；
    3)在步骤2)焊好夹心层的模具基体上，沿预留堆焊处余量形状以及夹心层的形状，堆焊强度和硬度较高的过渡层焊材，将夹心层焊材全部覆盖包住，并继续焊至模具型腔轮廓线下预先设计厚度处；
    4)在步骤3)过渡层焊材表面，堆焊高温耐磨的强化层焊材，覆盖模具主要耐磨工作区域或全部耐磨区域，焊至型腔轮廓线上预先设计厚度处；
    5)在步骤4)的模具基体上，按照预先设计的网状沟槽结构，加工出对应的网状沟槽结构，沟槽的深度及达夹心层焊材表面；
    6)在步骤5)的网状沟槽结构中，先用塑性好、延伸率高的普通软质材料堆焊填充，普通软质材料填充厚度与过渡层厚度一致，使普通软质材料表面与过渡层表面平齐；然后再用耐高温软质材料堆焊填充，耐高温软质材料填充厚度与强化层厚度一致，使耐高温软质材料表面与强化层表面平齐；
    7)将步骤6)得到的模具进行回火缓冷工艺、机械加工及其他后处理工序，即得权利要求2所述型腔表层随形网状结构化大型热锻模具。
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