阅读说明：本技术 一种高温合金异形截面法兰盘形件的模锻及轧制成形方法 (Die forging and roll forming method for high-temperature alloy special-shaped section flange disc-shaped part ) 是由 孙莉芳 蒲思洪 霍达 王世超 曹玉茹 周大云 马涛 张博 纪丽娜 张燕 于 2020-04-09 设计创作，主要内容包括：本发明公开了一种高温合金异形截面法兰盘形件的模锻及轧制成形方法,为获得具备复杂截面形状,尺寸精密,性能优异的高温合金法兰异形环件,其技术方案为：将锯切好的合金棒材加热至始锻温度并保温,经镦粗、冲孔两道工序制备近矩形环坯；采用局部开式模锻,对近矩形环坯靠近外圆部位的上下两端面施加压力,通过局部变形得到异形预制环坯；将异形预制环坯加热至高温合金的始锻温度并保温,随后放入轧环机中,利用主辊碾轧模具以相应转速结合芯辊径向进给速度对异形预制环坯进行轧环,得到高温合金法兰异形环件。本发明的一种高温合金异形截面法兰盘形件的模锻及轧制成形方法不仅能最大限度的简化生产流程,降低零件的生产成本,保证环件尺寸,而且该方法保留了的完整的锻件流线,确保环件具备良好的力学性能。(The invention discloses a die forging and roll forming method of a high-temperature alloy special-shaped section flange disc-shaped piece, which aims to obtain a high-temperature alloy flange special-shaped ring piece with a complex section shape, precise size and excellent performance, and adopts the technical scheme that: heating the sawed alloy bar to the initial forging temperature, preserving heat, and preparing a nearly rectangular ring blank through two working procedures of upsetting and punching; local open die forging is adopted, pressure is applied to the upper end face and the lower end face of the part, close to the excircle, of the approximately rectangular ring blank, and the special-shaped prefabricated ring blank is obtained through local deformation; and heating the special-shaped prefabricated ring blank to the initial forging temperature of the high-temperature alloy, preserving heat, then putting the special-shaped prefabricated ring blank into a ring rolling machine, and rolling the special-shaped prefabricated ring blank by using a main roller rolling die at a corresponding rotating speed in combination with the radial feeding speed of a core roller to obtain the special-shaped ring piece of the high-temperature alloy flange. The die forging and roll forming method for the high-temperature alloy special-shaped section flange disc-shaped piece can simplify the production flow to the maximum extent, reduce the production cost of parts and ensure the size of the ring piece, and the method reserves the complete forging flow line and ensures that the ring piece has good mechanical properties.)

1. A die forging and roll forming method for a high-temperature alloy special-shaped section flange disc-shaped part is characterized by comprising the following steps:

placing the approximately rectangular ring blank in a die for local die forging to prepare a special-shaped prefabricated ring blank;

heating the special-shaped prefabricated ring blank to 1000-1200 ℃ and preserving heat, wherein the shortest heat preservation time is not less than (0.4-1) min/mm multiplied by the effective thickness of the special-shaped prefabricated ring blank; and (4) rolling the ring after the heat preservation is finished, and finally obtaining the flange disc-shaped piece.

2. The die forging and roll forming method for the high-temperature alloy special-shaped section flange disc piece according to claim 1, wherein the preparation process of the approximately rectangular ring blank comprises the following steps: sawing the alloy bar according to a preset specification, heating the sawed alloy bar to 1000-1200 ℃, and preserving heat, wherein the shortest heat preservation time = (0.4-1) min/mm multiplied by the diameter of the alloy bar; then upsetting and punching are carried out to manufacture a nearly rectangular ring blank.

3. The die forging and roll forming method for the high-temperature alloy special-shaped section flange disc-shaped part according to claim 1, wherein local open die forging is adopted in the die forging process, pressure is only applied to the upper end face and the lower end face of the approximately rectangular ring blank close to the outer circle part, and local deformation is carried out to obtain the special-shaped prefabricated ring blank.

4. The die forging and roll forming method for the high-temperature alloy special-shaped section flange disc-shaped part according to claim 3, wherein the included angle between the two inclined planes at the outer circle part of the special-shaped prefabricated ring blank is 45-60 degrees.

5. A method of swaging and roll forming a superalloy profiled-section flange disc as in claim 3, wherein a maximum swaging pressure F is 1 x 10⁷N～2×10⁷N, the calculation mode is as follows: f =2 μ σ S, wherein μ is the friction coefficient of the ring material and the die, σ is the deformation resistance of the ring material at the finish forging temperature, and S is the projected area of the contact surface of the ring blank and the die.

6. The die forging and roll forming method for the high-temperature alloy special-shaped section flange disc piece according to claim 1, wherein in the ring rolling process, the optional rotation linear speed range of a main roller is 0.4-1.6 m/s, and the radial feeding speed of a core roller is divided into three stages: in the initial stage of ring rolling, the ring rolling stabilization stage and the ring rolling circle calibration and shaping stage, the radial feeding speed range of the core roller is 0-3 mm/s.

7. The die forging and roll forming method for high-temperature alloy special-shaped section flange disc-shaped piece according to claim 6, wherein the maximum ring rolling force range is 8 x 10 in the ring rolling process⁵N～1.7×10⁶N, is calculated as P =2kbL (1 +)h₀/4L+m3L/8 h₀+ m3L/4b), where k is the ring material shear yield strength, b is the ring height, L is the contact arc length, h₀Is the wall thickness of the ring member, and m is the friction factor.

8. The method for the local die forging blank making and ring rolling compound forming of the high-temperature alloy special-shaped section flange disc-shaped piece according to claim 1, wherein the rolling ratio lambda of the actual forming of the shield machine cutter ring special-shaped ring piece is 1-2.

9. The method for die forging and roll forming of a high temperature alloy profiled cross section flange disc shaped member as claimed in any one of claims 1 to 8, wherein the flange material is a high temperature alloy.

Technical Field

The invention belongs to the technical field of forging, and particularly relates to a die forging and roll forming method of a high-temperature alloy special-shaped section flange disc-shaped piece.

Background

The flange with the special-shaped cross section belongs to a special ring piece, is a key part at the connecting end of a pipeline, is very easy to damage due to the effect of pressure of flowing animal substances in the pipeline and the corrosion effect under a humid environment all the time, and needs to be frequently replaced to meet the requirement of pipeline performance indexes. Therefore, the manufacturing and forming technology of the special-shaped section flange which is simple and convenient in process, low in cost and easy for mass production is proposed. At present, the domestic main forming method of the special-shaped section flange comprises the following steps: integral open die forging or closed die forging forming, free forging of a nearly rectangular ring blank, direct multiple ring rolling forming, rolling of the rectangular ring blank and large-allowance machining forming. These methods are often influenced by factors such as the production cost of parts, comprehensive mechanical properties and dimensional requirements, and the expected ideal effect is difficult to achieve.

The die forging method has the advantages that the integral open die forging or closed die forging is adopted for forming, the size precision of parts is high, but the yield strength of materials in a pre-forging die cavity and a final forging die cavity in the forming process is high, the required tonnage of equipment is large, the die cavities are easy to lose effectiveness due to abrasion or cracking, the service life is short, and the production cost is high. And the trimming procedure after the integral open die forging can damage the integrity of a metal streamline of the forge piece, thereby influencing the mechanical property of the forge piece.

The method adopts freely forged nearly rectangular ring blanks and then directly rolls the ring by multiple times, the process is simple, but the number of the fire times of the rolled ring becomes a 'double-edged sword' which restricts the dimensional precision and the mechanical property of parts, the fire times of the rolled ring is few, the special-shaped part of the outer diameter of the ring piece is difficult to completely fill a rolling mould, and the dimensional requirement of a final product cannot be ensured; the ring is hot, which can easily cause the defects of coarse crystal grain, damage and crack of the forging, and increase the economic cost.

The process is simple, but the material utilization rate is low and the economic benefit is low. In addition, the machining seriously damages the integrity of the metal streamline of the forging and reduces the mechanical property of the part.

The Chinese patent with publication number CN101279346A discloses a rolling and forming method of a nickel-based superalloy deformed ring forging, which comprises the working procedures of blanking, upsetting, punching and rolling, wherein the method comprises the steps of primarily rolling the punched round cake-shaped forging twice with 20-25% deformation to obtain a rectangular prefabricated ring blank, and then rolling and forming for the third time by combining a rolling die and a ring rolling mill. The ring rolling process has the problems of multiple rolling fire, long production period and incomplete rolling mold filling in the process of converting the rectangular prefabricated ring blank into the special-shaped ring.

For another example, chinese patent publication No. CN103100620 discloses a rolling forming method for a high-temperature alloy ring member with a complex irregular cross section, which comprises heating a metal bar, upsetting, punching and ring-rolling the heated metal bar into a rectangular prefabricated ring blank, combining a pre-rolling inner mold module and a pre-rolling outer mold module to firstly prepare a irregular pre-rolling blank with a shape opposite to that of a finish-rolled irregular ring structure, and then rolling the irregular pre-rolling blank into an irregular cross section ring member through the finish-rolling inner mold module and the finish-rolling outer mold module. The method can overcome the problem of incomplete mold filling during rolling of the rectangular prefabricated ring blank, and the ring piece with high dimensional precision is rolled. However, the method needs frequent replacement of the rolling die, repeated rolling for many times invisibly increases economic cost, and is easy to cause defects of coarse grains, rolling damage, rolling cracks and the like of the structure of the forge piece.

Therefore, the invention discloses a die forging and roll forming method of a high-temperature alloy special-shaped section flange disc piece.

Disclosure of Invention

The invention aims to provide a die forging and roll forming method for a high-temperature alloy special-shaped section flange disc-shaped part. The method not only saves the process investment and the raw material consumption, does not need to rely on a die cavity with short service life and high cost, but also can ensure the streamline integrity of the forge piece to the maximum extent and ensure the mechanical property of the final product.

In order to achieve the purpose, the die forging and roll forming method for the high-temperature alloy special-shaped section flange disc piece adopts the following technical scheme that the method comprises the steps of preparing a nearly rectangular ring blank, preparing a special-shaped prefabricated ring blank and rolling a ring.

Further, the preparation of the near-rectangular ring blank comprises the following steps: sawing, heating, upsetting and punching.

The sawing step comprises the following steps: and sawing the alloy bar according to the preset specification.

The heating step is as follows: and heating the sawed alloy bar to the initial forging temperature of 1000-1200 ℃, and preserving heat, wherein the shortest heat preservation time is not (0.4-1) min/mm multiplied by the diameter of the alloy bar.

The upsetting step comprises the following steps: using a press machine, and upsetting the whole body to H = 90-130 mm after eliminating sharp corners by riveting and upsetting;

furthermore, in order to avoid the temperature rise of the material caused by excessive deformation, the deformation during upsetting is controlled to be 30-60 percent.

The punching step comprises the following steps: punching with a punch with the diameter of 130-150 mm and the thickness of the punching bottom sheet less than or equal to 45mm to prepare the nearly rectangular ring piece.

Further, the production of the profiled ring preform comprises: and local die forging.

The local die forging step is as follows: open die forging is adopted on a press, a nearly rectangular ring blank is placed into a preheated die, pressure is only applied to the upper end surface and the lower end surface of the nearly rectangular ring blank close to the excircle, and local deformation is carried out to prepare a special-shaped prefabricated ring blank;

further, the included angle of the two inclined planes at the excircle part of the special-shaped prefabricated ring blank is 45-60 degrees;

further, the maximum die forging pressure F is 1X 10⁷N～2×10⁷N；

Further, the maximum die forging pressure is calculated in the following manner: f =2 μ σ S, wherein μ is the friction coefficient of the ring material and the die, σ is the deformation resistance of the ring material at the finish forging temperature, and S is the projected area of the contact surface of the ring blank and the die.

Further, the rolling ring comprises: heating and rolling.

The heating step is as follows: and heating the special-shaped prefabricated ring blank to the initial forging temperature of 1000-1200 ℃, and preserving heat, wherein the shortest heat preservation time = (0.4-1.0) min/mm multiplied by the effective section thickness of the special-shaped prefabricated ring blank.

The rolling step comprises the following steps: placing the heated special-shaped prefabricated ring blank on a ring rolling machine, enabling an external convex part of the special-shaped prefabricated ring blank to correspond to an internal concave part of a main roller mold, moving the main roller mold at an axial autorotation linear velocity, moving a core roller at a certain radial feeding velocity, and rolling the special-shaped prefabricated ring blank to a required size and shape;

further, the optional axial rotation linear velocity range of the main roller is 0.4-1.6 m/s, and the radial feeding velocity of the core roller is divided into three stages: in the ring rolling initial stage, the ring rolling stabilization stage and the ring rolling roundness correction stage, the radial feeding speed range is 0-3 mm/s;

further, in the initial ring rolling stage, the core roller feeds the special-shaped prefabricated ring blank into a ring rolling die through radial feed motion, so that the blank is ensured to be in contact with the die and the ring rolling is started; in the ring rolling stabilization stage, the axial autorotation motion of the main roller is combined with the radial feed motion of the core roller, so that the special-shaped prefabricated ring blank is ensured to be continuously and stably filled in a ring rolling die; in the ring rolling and rounding stage, the core roller does not perform radial feeding motion, only the main roller performs axial rotation motion, and the ring piece is rounded and rounded, so that the size precision of the final ring piece is ensured;

furthermore, in the ring rolling process, the maximum ring rolling force range is 8 multiplied by 10⁵N～1.7×10⁶N；

Further, the calculation method was P =2kbL (1+ h)₀/4L+m3L/8 h₀+ m3L/4b), where k is the ring material shear yield strength, b is the ring height, L is the contact arc length, h₀The wall thickness of the ring piece, m is a friction factor;

further, the actual forming deformation is the rolling ratio lambda of the sectional area of the intermediate blank of the ring blank after the open die forging local deformation to the sectional area of the final ring piece.

The invention discloses a local die forging and ring rolling composite forming method of a flange disc-shaped piece, which adopts the technical scheme of saw cutting, heating, upsetting, punching, die forging and ring rolling.

Compared with the prior art, the invention has the following advantages: large allowance machining is not needed, no trimming step is needed, the material utilization rate is improved to the maximum extent, and the integrity of a forging flow line is reserved; multiple ring rolling is not needed, and the special-shaped prefabricated ring blank prepared by local die forging can be completely filled in a ring rolling die; the process is simple, complex forging impression and large-tonnage complex forming equipment are not needed, the cost of the forge piece is saved, and the technology is suitable for various enterprises.

Drawings

The invention is further described with reference to the following figures and specific embodiments.

FIG. 1 is a schematic view of partial swaging in the present invention; wherein: 1. an upper die; 2. a nearly rectangular ring blank; 3. and (5) a lower die.

Fig. 2 is a schematic view of a partially swaged profiled preform in accordance with the present invention.

Fig. 3 is a schematic view of a main roll rolling mold according to the present invention.

FIG. 4 is a schematic view of the special-shaped preform ring shown in FIG. 2, which is rolled in the rolling mold of FIG. 4 to form a ring shape. Wherein: 6. an upper shoulder; 7. a lower shoulder; 8. an upper inclined plane of the special-shaped prefabricated ring blank; 9. and (5) performing special-shaped prefabricated ring blank lower inclined plane. 10. A V-shaped groove is arranged; 11. a V-shaped groove is arranged; 12. internal U-shaped groove

Fig. 5 is a schematic view of the final special-shaped ring piece after the ring rolling forming of the invention.

Detailed Description

Example 1

In the present embodiment, the specific implementation of the method is described in detail by taking alloy with the designation GH2132 as an example:

the GH2132 alloy comprises the following main chemical elements:

TABLE 1 main chemical elements of GH2132 alloy

Element(s)

C

Cr

Ni

V

Fe

Mo

Al

Content (%)

≤0.08

13.5～16.0

24.0～27.0

0.10～0.50

Balance of

1.00～1.50

≤0.35

Ti

S

B

Mn

Si

P

1.75～2.30

≤0.02

0.003～0.010

≤0.35

0.25～0.75

≤0.015

The method for implementing the local die forging of the flange plate-shaped piece and the composite forming of the rolled ring needs to provide a band sawing machine, a forging heating furnace, a press machine, a ring rolling machine and a manipulator.

The die forging and roll forming method for the high-temperature alloy special-shaped section flange disc-shaped piece adopts the following technical scheme that the die forging and roll forming method comprises the following steps: preparing a nearly rectangular ring blank, preparing a special-shaped prefabricated ring blank, and rolling a ring.

Further, the preparation of the near-rectangular ring blank comprises the following steps: sawing, heating, upsetting and punching.

The sawing step comprises the following steps: and sawing the GH2132 alloy bar according to a preset specification.

The heating step is as follows: heating the sawed GH2132 alloy bar to the initial forging temperature of 1120 ℃ and preserving heat, wherein the shortest preserving time =0.8min/mm multiplied by the GH2132 alloy bar diameter of 185 mm.

The upsetting step comprises the following steps: using a press machine, and upsetting the whole body to H =100 +/-5 mm after eliminating sharp corners by riveting and upsetting;

furthermore, in order to avoid the temperature rise of the GH2132 alloy caused by excessive deformation, the deformation during upsetting is controlled to be 30-35%.

The punching step comprises the following steps: punching a hole with the diameter of 130mm plus or minus 5mm by using a punch, and preparing a nearly rectangular ring piece 2, wherein the thickness of a punching bottom sheet is 40 mm;

further, the preparation of the special-shaped prefabricated ring blank comprises the following steps: and local die forging.

The local die forging step is as follows: as shown in fig. 1, open die forging is adopted on a press, a nearly rectangular ring blank 2 is placed between a preheated upper die 1 and a preheated lower die 3, pressure is only applied to the upper end surface and the lower end surface of the nearly rectangular ring blank 2 close to the excircle part, and local deformation is carried out to prepare a GH2132 special-shaped prefabricated ring blank 4;

further, the included angle alpha of two inclined planes at the excircle part of the GH2132 special-shaped prefabricated ring blank 4 is 50 degrees;

further, the die forging pressure F was 1.18X 10⁷N；

Further, the maximum die forging pressure is calculated in the following manner: f =2 μ σ S, wherein μ is the friction coefficient of the GH2132 alloy ring material and the die, μ =0.28, σ is the deformation resistance of GH2132 at the finish forging temperature of 900 ℃, σ =381MPa, S is the projected area of the contact surface of the ring blank 2 and the die 1, and S =550.6cm²。

The local open die forging has the following process characteristics: the forging flow lines generated in the special-shaped prefabricated ring blank are distributed along the contour of the forging piece along the shape, so that the comprehensive mechanical property of the ring blank is favorably improved; the special-shaped prefabricated ring blank has no burrs, trimming is not needed in later processing, and the material utilization rate is high; only local deformation of the nearly rectangular ring blank is realized, the die is simple, the tonnage of required equipment is small, and the production cost is low.

The local open die forging can obviously reduce the yield strength of materials in the forging process, reduce the dependence on large-tonnage die forging equipment, quickly obtain the special-shaped prefabricated ring blank which can ensure the size and quality requirements of the final rolled ring, and has low production cost and high production efficiency. The local open die forging does not damage the integrity of a forging streamline, so that the ring rolling forming quality and the batch stability of the ring piece are high.

Further, the rolling ring comprises: heating and rolling.

The heating step is as follows: and heating the special-shaped prefabricated ring blank 4 to the initial forging temperature of 1120 ℃ and preserving heat, wherein the shortest heat preservation time =0.8min/mm multiplied by the effective section thickness of the special-shaped prefabricated ring blank of 90 mm.

The rolling step comprises the following steps: placing the heated special-shaped prefabricated ring blank 4 on a ring rolling machine, enabling an external convex part of the special-shaped prefabricated ring blank 4 to correspond to an internal concave part of a main roller mold 5, and rolling the special-shaped prefabricated ring blank 4 to the required shape and size by combining the axial rotation linear speed of the main roller mold 5 with the axial rotation linear speed of 1.4m/s and the radial feeding speed of a core roller with the axial rotation linear speed of 1.2 mm/s;

further, in the ring rolling process, the process of gradually filling the main roll mold of the ring rolling machine with metal through plastic deformation is shown in fig. 4. In the initial stage of ring rolling, as shown in fig. 4a, the core roller feeds the special-shaped prefabricated ring blank 4 into the rolling main roller die 5 by radial feed motion, the blank contacts with the die and starts to roll the ring, and the upper shoulder 6 and the lower shoulder 7 of the main roller die 5 respectively extrude the upper inclined surface 8 and the lower inclined surface 9 of the special-shaped prefabricated ring blank 4. According to the principle that the volume of metal is not changed in plastic deformation and the law of minimum resistance, along with the gradual increase of the diameter of the ring blank, the metal at the upper inclined surface 8 and the lower inclined surface 9 of the special-shaped prefabricated ring blank 4 flows to the axial and radial vacant areas in the main roller mold 5; in the ring rolling stabilization stage, as shown in fig. 4b and 4c, the radial feed motion of the core roller is combined with the axial rotation motion of the main roller, and the special-shaped prefabricated ring blank 4 firstly completes the filling of an upper V-shaped groove 10 and a lower V-shaped groove 11 outside an upper shoulder 6 and a lower shoulder 7 in the main roller mold 5 and then completes the filling of a U-shaped groove 12 inside the upper shoulder 6 and the lower shoulder 7 in the main roller mold 5; and (3) performing rolling ring rounding and shaping, namely performing rolling ring rounding and shaping on the ring piece, wherein the rolling ring rounding and shaping stage is shown in fig. 4d, the core roller does not perform radial feeding motion, only the main roller performs axial autorotation motion, and the ring piece is rounded and shaped to finally obtain the high-temperature alloy flange special-shaped ring piece shown in fig. 5.

Furthermore, in the ring rolling process, the maximum ring rolling force is 8.7 multiplied by 10⁵N；

Further, the maximum ring rolling force was calculated in a manner of P =2kbL (1+ h)₀/4L+m3L/8 h₀+ m3L/4b), where k is the ring material shear yield strength, k =219.97MPa, b is the ring height, b =89mm, L is the contact arc length, L =1.7mm, h₀Is the wall thickness of the ring member, h₀=82mm, m is the friction factor, m = 0.67;

further, the actual forming deformation is the rolling ratio lambda of the sectional area of the intermediate blank of the ring blank after the open die forging local deformation to the sectional area of the final ring piece. In this embodiment, the sectional area of the intermediate blank of the ring blank after the local die forging deformation is 7569mm²The final ring cross-sectional area is 4836 mm²And λ is 1.56.

The invention discloses a flange local die forging and ring rolling composite forming method, which adopts the technical scheme of saw cutting, heating, upsetting, punching, die forging and ring rolling.

Compared with the prior art, the invention has the following advantages: large allowance machining is not needed, no trimming step is needed, the material utilization rate is improved to the maximum extent, and the integrity of a forging flow line is reserved; multiple ring rolling is not needed, and the special-shaped prefabricated ring blank prepared by local die forging can be completely filled in a ring rolling die; the process is simple, complex forging impression and large-tonnage complex forming equipment are not needed, the cost of the forge piece is saved, and the technology is suitable for various enterprises.

Therefore, the die forging and roll forming method for the high-temperature alloy special-shaped section flange disc-shaped piece can effectively simplify the process flow, can manufacture the flange disc-shaped piece with excellent mechanical property by using a low-cost process method and low-cost equipment, has wide technical application prospect, and is suitable for popularization in various enterprises.

Example 2

In the present embodiment, the specific implementation of the method is described in detail by taking alloy No. GH4169 as an example:

the main chemical element contents of the GH4169 alloy are as follows:

TABLE 2 main chemical elements of GH4169 alloy

Element(s)

C

Cr

Ni

Co

Nb

Mo

Al

Content (%)

0.02～0.06

17.0～21.00

50.0～55.0

≤1.00

4.75～5.50

2.80～3.30

0.20～0.80

Ti

Fe

B

Mn

Si

P

S

Cu

0.65～1.15

Balance of

≤0.006

≤0.35

≤0.35

≤0.015

≤0.015

≤0.30

The method for implementing the local die forging and the ring rolling composite forming of the high-temperature alloy special-shaped section flange disc-shaped piece needs to provide a band sawing machine, a forging heating furnace, a press machine, a ring rolling machine and a manipulator.

The invention discloses a local die forging blank making and ring rolling composite forming method for a high-temperature alloy flange special-shaped ring piece.

Further, the preparation of the near-rectangular ring blank comprises the following steps: sawing, heating, upsetting and punching.

The sawing step comprises the following steps: and sawing the GH4169 alloy bar according to a preset specification.

The heating step is as follows: heating the sawn GH4169 alloy bar to the initial forging temperature of 1020 ℃ and preserving heat, wherein the shortest preserving time =0.6min/mm multiplied by the GH4169 alloy bar diameter of 195 mm.

The upsetting step comprises the following steps: using a press machine, and upsetting the whole body to H =95 +/-5 mm after eliminating sharp corners by riveting and upsetting;

furthermore, in order to avoid the temperature rise of the GH4169 alloy caused by excessive deformation, the deformation amount during upsetting is controlled to be 40-45%.

The punching step comprises the following steps: punching phi 135 +/-5 mm by using a punch, and punching the bottom sheet to be 40mm in thickness to prepare the GH4169 alloy approximately-rectangular ring piece 2.

Further, the preparation of the special-shaped prefabricated ring blank comprises the following steps: and local die forging.

The local die forging step is as follows: as shown in fig. 1, open die forging is adopted on a press, a rectangular ring blank 2 is placed between a preheated upper die 1 and a preheated lower die 3, pressure is only applied to the upper end surface and the lower end surface of the rectangular ring blank 2 close to the excircle part, and local deformation is carried out to prepare a GH4169 special-shaped prefabricated ring blank 4;

further, the included angle alpha of two inclined planes at the excircle part of the GH4169 special-shaped prefabricated ring blank 4 is 53 degrees;

further, the maximum die forging pressure F is 1.52X 10⁷N；

Further, the maximum die forging pressure is calculated in the following manner: f =2 μ σ S, wherein μ is the friction coefficient of GH4169 material and the die, μ =0.28, σ is the deformation resistance of GH4169 at the finish forging temperature 930 ℃, σ =532MPa, S is the projection area of the contact surface of the ring blank 2 and the die 1, and S =510.4cm²。

The local open die forging has the following process characteristics: the forging flow lines generated in the special-shaped prefabricated ring blank are distributed along the contour of the forging piece along the shape, so that the comprehensive mechanical property of the ring blank is favorably improved; the special-shaped prefabricated ring blank has no burrs, trimming is not needed in later processing, and the material utilization rate is high; only local deformation of the nearly rectangular ring blank is realized, the die is simple, the tonnage of required equipment is small, and the production cost is low.

The local open die forging can obviously reduce the yield strength of materials in the forging process, reduce the dependence on large-tonnage die forging equipment, quickly obtain the special-shaped prefabricated ring blank which can ensure the size and quality requirements of the final rolled ring, and has low production cost and high production efficiency. The local open die forging does not damage the integrity of a forging streamline, so that the ring rolling forming quality and the batch stability of the ring piece are high.

Further, the rolling ring comprises: heating and rolling.

The heating step is as follows: and heating the special-shaped prefabricated ring blank 4 to the initial forging temperature of 1020 ℃ and preserving heat, wherein the shortest heat preservation time =0.6min/mm multiplied by GH4169 effective section thickness of the special-shaped prefabricated ring blank is 95 mm.

The ring rolling step comprises: placing the heated special-shaped prefabricated ring blank 4 on a ring rolling machine, enabling an external convex part of the special-shaped prefabricated ring blank 4 to correspond to an internal concave part of a main roller mold 5, and rolling the special-shaped prefabricated ring blank 4 to the required shape and size by combining the axial rotation linear speed of the main roller mold 5 with the axial rotation linear speed of 1.0m/s and the radial feeding speed of a core roller with the axial rotation linear speed of 0.8 mm/s;

further, in the ring rolling process, the process of gradually filling the main roll mold of the ring rolling machine with metal through plastic deformation is shown in fig. 4. In the initial stage of ring rolling, as shown in fig. 4a, the core roller feeds the special-shaped prefabricated ring blank 4 into the rolling main roller die 5 through radial feed motion, the blank contacts with the die and starts to roll the ring, and the upper shoulder 6 and the lower shoulder 7 of the main roller die 5 respectively extrude the upper inclined surface 8 and the lower inclined surface 9 of the special-shaped prefabricated ring blank 4. According to the principle that the volume of metal is not changed in plastic deformation and the law of minimum resistance, along with the gradual increase of the diameter of the ring blank, the metal at the upper inclined surface 8 and the lower inclined surface 9 of the special-shaped prefabricated ring blank 4 flows to the axial and radial vacant areas in the main roller mold 5; in the ring rolling stabilization stage, as shown in fig. 4b and 4c, the radial feed motion of the core roller is combined with the axial rotation motion of the main roller, and the special-shaped prefabricated ring blank 4 firstly completes the filling of an upper V-shaped groove 10 and a lower V-shaped groove 11 outside an upper shoulder 6 and a lower shoulder 7 in the main roller mold 5 and then completes the filling of a U-shaped groove 12 inside the upper shoulder 6 and the lower shoulder 7 in the main roller mold 5; and (3) performing rolling ring rounding and shaping, namely performing rolling ring rounding and shaping on the ring piece, wherein the rolling ring rounding and shaping stage is shown in fig. 4d, the core roller does not perform radial feeding motion, only the main roller performs axial autorotation motion, and the ring piece is rounded and shaped to finally obtain the high-temperature alloy flange special-shaped ring piece shown in fig. 5.

Furthermore, in the ring rolling process, the maximum ring rolling force is 1.38 multiplied by 10⁶N；

Further, the maximum ring rolling force was calculated in a manner of P =2kbL (1+ h)₀/4L+m3L/8 h₀+ m3L/4b), where k is the ring material shear yield strength, k =307.15MPa, b is the ring height, b =87mm, L is the contact arc length, L =1.67mm,h0 is ring wall thickness h₀=96.5mm, m is the friction factor, m = 0.67;

further, the actual forming deformation is the rolling ratio lambda of the sectional area of the intermediate blank of the ring blank after the open die forging local deformation to the sectional area of the final ring piece. In this example, the sectional area of the intermediate billet of the ring blank after the local die forging deformation was 9211mm²The sectional area of the final ring piece is 5984 mm²And λ is 1.53.

The invention discloses a flange local die forging and ring rolling composite forming method, which adopts the technical scheme of saw cutting, heating, upsetting, punching, die forging and ring rolling.

Compared with the prior art, the invention has the following advantages: large allowance machining is not needed, no trimming step is needed, the material utilization rate is improved to the maximum extent, and the integrity of a forging flow line is reserved; multiple ring rolling is not needed, and the special-shaped prefabricated ring blank prepared by local die forging can be completely filled in a ring rolling die; the process is simple, complex forging impression and large-tonnage complex forming equipment are not needed, the cost of the forge piece is saved, and the technology is suitable for various enterprises.

Therefore, the die forging and roll forming method for the high-temperature alloy special-shaped section flange disc-shaped piece can effectively simplify the process flow, can manufacture the flange disc-shaped piece with excellent mechanical property by using a low-cost process method and low-cost equipment, has wide technical application prospect, and is suitable for being popularized in small and medium-sized enterprises.

Example 3

In this example, the specific implementation of the method is described in detail by taking alloy No. GH536 as an example:

the GH536 alloy comprises the following main chemical elements:

TABLE 3 main chemical elements of GH536 alloy

Element(s)

C

Cr

Ni

Co

W

Mo

Al

Content (%)

0.05～0.15

20.50～23.00

Balance of

0.50～2.50

0.20～1.00

8.00～10.00

≤0.50

Ti

Fe

B

Mn

Si

P

S

Cu

≤0.15

17.00～20.00

≤0.010

≤1.00

≤1.00

≤0.025

≤0.015

≤0.50

The method for implementing the local die forging of the flange plate-shaped piece and the composite forming of the rolled ring needs to provide a band sawing machine, a forging heating furnace, a press machine, a ring rolling machine and a manipulator.

The invention discloses a local die forging blank making and ring rolling composite forming method for a high-temperature alloy flange special-shaped ring piece.

Further, the preparation of the near-rectangular ring blank comprises the following steps: sawing, heating, upsetting and punching.

The sawing step comprises the following steps: and sawing the GH536 alloy bar according to the preset specification.

The heating step is as follows: and heating the sawed GH536 alloy bar to the forging starting temperature of 1150 ℃ and preserving heat, wherein the minimum preserving time =0.7min/mm multiplied by the diameter of the alloy bar of 205 mm.

The upsetting step comprises the following steps: and using a press, and upsetting the whole body to H =112 +/-5 mm after eliminating sharp corners by riveting and upsetting.

Furthermore, in order to avoid the temperature rise of GH536 caused by excessive deformation, the deformation during upsetting is controlled to be 45-50%.

The punching step comprises the following steps: punching phi 140 +/-5 mm by using a punch, and punching the bottom plate to be 45mm in thickness to prepare the GH536 approximately rectangular ring piece 2.

Further, the preparation of the special-shaped prefabricated ring blank comprises the following steps: and local die forging.

The local die forging step is as follows: as shown in fig. 1, open die forging is adopted on a press, a rectangular ring blank 2 is placed between a preheated upper die 1 and a preheated lower die 3, pressure is applied to the upper end surface and the lower end surface of the rectangular ring blank 2 close to the excircle part, and local deformation is carried out to prepare a GH536 special-shaped prefabricated ring blank 4;

furthermore, the included angle alpha of the two inclined planes at the excircle part of the GH536 special-shaped precast ring blank 4 is 55 degrees;

further, the maximum die forging pressure F is 1.49X 10⁷N；

Further, the maximum die forging pressure is calculated in the following manner: f =2 μ σ S, wherein μ is the friction coefficient of the GH536 alloy ring material and the die, μ =0.28, σ is the deformation resistance of the GH536 alloy at the finish forging temperature of 850 ℃, σ =416MPa, S is the projected area of the contact surface of the ring blank 2 and the die 1, and S =640.2cm²。

The local open die forging has the following process characteristics: the forging flow lines generated in the special-shaped prefabricated ring blank are distributed along the contour of the forging piece along the shape, so that the comprehensive mechanical property of the ring blank is favorably improved; the special-shaped prefabricated ring blank has no burrs, trimming is not needed in later processing, and the material utilization rate is high; only local deformation of the nearly rectangular ring blank is realized, the die is simple, the tonnage of required equipment is small, and the production cost is low.

The local open die forging can obviously reduce the yield strength of materials in the forging process, reduce the dependence on large-tonnage die forging equipment, quickly obtain the special-shaped prefabricated ring blank which can ensure the size and quality requirements of the final rolled ring, and has low production cost and high production efficiency. The local open die forging does not damage the integrity of a forging streamline, so that the ring rolling forming quality and the batch stability of the ring piece are high.

Further, the rolling ring comprises: heating and rolling.

The heating step is as follows: and heating the special-shaped prefabricated ring blank 4 to the initial forging temperature of 1150 ℃ and preserving heat, wherein the shortest heat preservation time =0.7min/mm multiplied by the effective section thickness of the special-shaped prefabricated ring blank of 100 mm.

The rolling step comprises the following steps: placing the heated special-shaped prefabricated ring blank 4 on a ring rolling machine, enabling an external convex part of the special-shaped prefabricated ring blank 4 to correspond to an internal concave part of a main roller mold 5, and rolling the special-shaped prefabricated ring blank 4 to the required shape and size by combining the axial rotation linear speed of the main roller mold 5 with the axial rotation linear speed of 1.2m/s and the core roller feeding speed of 1.0 mm/s;

further, in the ring rolling process, the process of gradually filling the main roll mold of the ring rolling machine with metal through plastic deformation is shown in fig. 4. In the initial stage of ring rolling, as shown in fig. 4a, the core roller feeds the special-shaped prefabricated ring blank 4 into the rolling main roller die 5 by radial feed motion, the blank contacts with the die and starts to roll the ring, and the upper shoulder 6 and the lower shoulder 7 of the main roller die 5 respectively extrude the upper inclined surface 8 and the lower inclined surface 9 of the special-shaped prefabricated ring blank 4. According to the principle that the volume of metal is not changed in plastic deformation and the law of minimum resistance, along with the gradual increase of the diameter of the ring blank, the metal at the upper inclined surface 8 and the lower inclined surface 9 of the special-shaped prefabricated ring blank 4 flows to the axial and radial vacant areas in the main roller mold 5; in the ring rolling stabilization stage, as shown in fig. 4b and 4c, the radial feed motion of the core roller is combined with the axial rotation motion of the main roller, and the special-shaped prefabricated ring blank 4 firstly completes the filling of an upper V-shaped groove 10 and a lower V-shaped groove 11 outside an upper shoulder 6 and a lower shoulder 7 in the main roller mold 5 and then completes the filling of a U-shaped groove 12 inside the upper shoulder 6 and the lower shoulder 7 in the main roller mold 5; the rolling ring rounding stage is as shown in fig. 4d, the core roller does not perform radial feed motion, only the main roller performs axial rotation motion, the ring is rounded, and finally the high-temperature alloy flange special-shaped ring as shown in fig. 5 is obtained;

furthermore, in the ring rolling process, the maximum ring rolling force is 1.1 multiplied by 10⁶N；

Further, the maximum ring rolling force was calculated in a manner of P =2kbL (1+ h)₀/4L+m3L/8 h₀+ m3L/4b), where k is the ring material shear yield strength, k =240.18MPa, b is the ring height, b =100mm, L is the contact arc length, L =1.68mm, h₀Is the wall thickness of the ring member, h₀=85mm, m is the friction factor, m = 0.67;

further, the actual forming deformation is the rolling ratio lambda of the sectional area of the intermediate blank of the ring blank after the open die forging local deformation to the sectional area of the final ring piece. In this embodiment, the cross-sectional area of the intermediate blank of the ring blank after the local die forging deformation is 9415mm²The sectional area of the final ring piece is 5348 mm²And λ is 1.76.

The invention discloses a method for the local die forging and ring rolling composite forming of a flange, which adopts the technical scheme of saw cutting, heating, upsetting, punching, die forging and ring rolling.

Compared with the prior art, the invention has the following advantages: large allowance machining is not needed, no trimming step is needed, the material utilization rate is improved to the maximum extent, and the integrity of a forging flow line is reserved; multiple ring rolling is not needed, and the special-shaped prefabricated ring blank prepared by local die forging can be completely filled in a ring rolling die; the process is simple, complex forging impression and large-tonnage complex forming equipment are not needed, the cost of the forge piece is saved, and the technology is suitable for various enterprises.

Therefore, the die forging and roll forming method for the high-temperature alloy special-shaped section flange disc-shaped piece can effectively simplify the process flow, can manufacture the flange disc-shaped piece with excellent mechanical property by using a low-cost process method and low-cost equipment, has wide technical application prospect, and is suitable for popularization in various enterprises.

The foregoing examples and description merely illustrate the principles of the present invention and are not intended to limit the scope of the method. For the special-shaped ring forgings with different shapes, special-shaped ring pieces with different cross-sectional shapes can be prepared only by changing the shape of a die cavity of a local die forging and the shape of a ring rolling die. Various non-inventive changes and modifications related to the present invention are within the scope of the present invention.